Rearview mirror assembly for vehicle

ABSTRACT

A vehicular interior rearview mirror assembly includes a mirror reflective element having a glass substrate with a planar front surface and a circumferential edge along the periphery of the glass substrate. A mounting element is disposed at the rear of the mirror reflective element and includes a pivot element that is configured to pivotally mount the mirror reflective element at the vehicle. A plastic molding receives the mirror reflective element therein such that a portion of the plastic molding is circumferentially disposed about the circumferential edge of the glass substrate without overlapping onto the front surface of the glass substrate. The portion of the plastic molding provides a curved rounded transition from the front surface of the glass substrate to a side surface of the plastic molding. The plastic molding includes at least a portion of a mirror housing of the interior rearview mirror assembly.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 15/413,465, filed Jan. 24, 2017, now U.S. Pat. No. 9,783,115,which is a continuation of U.S. patent application Ser. No. 13/964,135,filed Aug. 12, 2013, now U.S. Pat. No. 9,557,584, which is acontinuation of U.S. patent application Ser. No. 13/689,800, filed Nov.30, 2012, now U.S. Pat. No. 8,508,384, which is a continuation of U.S.patent application Ser. No. 13/284,197, filed Oct. 28, 2011, now U.S.Pat. No. 8,325,055, which is a continuation of U.S. patent applicationSer. No. 13/035,297, filed Feb. 25, 2011, now U.S. Pat. No. 8,049,640,which is a continuation of U.S. patent application Ser. No. 11/926,882,filed Oct. 29, 2007, now U.S. Pat. No. 7,978,094, which is acontinuation of U.S. patent application Ser. No. 10/556,754, filed Nov.15, 2005, now U.S. Pat. No. 7,289,037, which is a 371 U.S. nationalphase application of PCT Application No. PCT/US2004/015424, filed May18, 2004, which claims benefit of U.S. provisional applications, Ser.No. 60/556,259, filed Mar. 25, 2004; Ser. No. 60/525,537, filed Nov. 26,2003; and Ser. No. 60/471,546, filed May 19, 2003, which are herebyincorporated herein by reference in their entireties.

FIELD OF THE INVENTION

The present invention relates generally to the field of interiorrearview mirror assemblies for vehicles and, more particularly, tointerior rearview mirror assemblies which incorporate an accessory orfeature, particularly an electronic accessory or feature.

BACKGROUND OF THE INVENTION

The base level mirror for a vehicle is often a prismatic mirrorassembly, which may provide a low cost mirror for the vehicle. Themirror assembly is often economically assembled by snapping or insertingthe toggle assembly and prismatic reflective element into the casing atthe front or bezel portion of the mirror casing substantiallyimmediately after the casing (which may be formed of a hot moldedpolypropylene or the like) is formed and while the casing is still hotand pliable. As the casing cools, it shrinks to secure the reflectiveelement in place in the casing. Because the reflective element isinserted into the casing while the casing is hot (such as after beingfreshly molded), the timing for the insertion process may be limited.Thus, it may be difficult to install or insert other accessories orcomponents into the casing before the casing cools and shrinks.

It is often desirable to provide an electronic feature in the mirrorassembly, such as a compass sensor and/or compass display, a tirepressure monitoring system and/or display and/or the like. In order tofacilitate the addition of accessories or other components in the mirrorassembly, the mirror assembly may typically have a casing and a separatebezel portion, which allows the accessory or accessories or the like tobe installed into the casing (via its front opening) after it hascooled, and then allows the reflective element and bezel portion to beinstalled at the front portion of the casing. The bezel portion may besnapped to the casing or may be otherwise attached to the casing viasonic welding or the like to secure the bezel portion to the casing andto secure the components or accessories and the reflective element at orwithin the mirror casing. Although practical, this involves a lesseconomical two-part, non-unitary casing and bezel design.

It is typically preferred to have the unitarily formed casing and bezelportion so that the reflective element is inserted into the casing whilethe casing is hot and pliable. However, it is also desirable to provideadditional features or functions to the mirror assembly. Therefore,there is a need in the art for an improved mirror assembly whichovercomes the shortcomings of the prior art.

SUMMARY OF THE INVENTION

The present invention provides an interior rearview mirror assemblywhich has one or more cap portions which attach or secure to a rearportion of a mirror holder. The mirror holder comprises part of areflective element assembly portion comprising a mirror reflectiveelement and a bezel portion or the like that preferably encompasses atleast a perimeter portion of the reflective element, thereby at leastpartially securing the reflective element in the reflective elementassembly portion. The cap portion or portions may include one or moreelectronic accessories or circuitry to provide additional features orfunctions to the mirror assembly. The additional features or functionsmay thus be back-loaded into the mirror holder after the mirror holderis formed and after the reflective element is attached at the bezelportion or front portion of the mirror holder.

According to an aspect of the present invention, an interior rearviewmirror assembly for a vehicle comprises a mirror holder having a frontportion and a rear portion, a reflective element positioned at the frontportion of the mirror holder and received at least partially within thefront portion of the mirror holder, and at least one cap portion. Therear portion of the mirror holder has at least one opening therethroughand the at least one cap portion is attachable to the rear portion ofthe mirror holder generally at the at least one opening. The at leastone cap portion includes circuitry for at least one accessory. The atleast one cap portion provides a rear cover for the mirror holdergenerally over the at least one opening.

According to another aspect of the present invention, a method ofmanufacturing an interior rearview mirror assembly portion includesforming a first molding by injection molding a first resinous materialin a mold. The first resinous material has a tool shrinkage factor of atleast approximately 1%. The first molding is at an elevated temperaturewhen the first molding is removed from the mold. A reflective element isprovided and positioned at the first molding before the first moldinghas cooled to approximately ambient temperature. The first molding atleast partially encompasses a perimeter portion of the reflectiveelement to form a reflective element assembly portion. The first moldingis allowed to cool and shrink to retain the reflective element at thefirst molding. A cap portion comprises a second resinous material, whichhas a tool shrinkage factor of at less than or equal to approximately1%. The cap portion includes at least one accessory. The cap portion isattached to the reflective element assembly portion after the firstmolding has cooled and shrunk. The cap portion is attached to thereflective element assembly portion such that the accessory is at leastpartially within the mirror assembly.

The accessory may comprise a compass sensor and/or display, a tirepressure monitoring system receiver/control circuitry and/or display, anantenna, a garage door opener, or any other accessory and/or accessorydisplay and associated circuitry. For example, the circuitry maycomprise compass display circuitry and the reflective element may haveat least one port or icon or character etched or otherwise formedthereon, and preferably with an element of the circuitry alignedwith/juxtaposed with the at least one port or icon or character etchedor otherwise formed on the reflective element. The display circuitry mayinclude at least one illumination source or lighting element forprojecting illumination through a corresponding or appropriate port oricon or character on the mirror reflective element.

The cap portion or portions may be detachably attached to the mirrorholder or first molding or bezel portion, such as via accessible detentsor snaps or the like, and may be detachably removable from the mirrorholder or first molding or bezel portion for service or replacement.However, the cap portion may alternatively be non-detachably attached,such as by adhesive attachment or by heat staking or by ultrasonicwelding or the like.

Therefore, the present invention provides an interior rearview mirrorassembly which may include one or more electronic accessories orfeatures. The accessory or feature may be installed at the rear portionof the mirror holder or bezel portion opposite the reflective element,and may be installed after the reflective element is inserted into thefreshly molded or hot mirror holder or bezel portion and after themirror holder has cooled and shrunk to secure the reflective element.Preferably, the accessory or feature may be mounted or positioned at,within or on one or more cap portions (preferably also with anyassociated wiring, interconnects and/or connectors and the like) whichmay be secured to the rear portion of the mirror holder and which mayform a rear wall or surface of the mirror holder. The cap portion may besnapped to or attached to the mirror holder (which has the reflectiveelement already inserted/installed therein) after the mirror holder hascooled, such that the assembly may be completed at a facility orassembly line that is remote from the facility or line at which thereflective element and mirror holder are assembled together. The presentinvention thus facilitates the addition of an electronic accessory orfeature into a low cost mirror assembly with minimal additionalinvestment to add the accessory or feature. The present invention maythus easily accommodate various features which may be selected by acustomer.

These and other objects, advantages, purposes and features of thepresent invention will become apparent upon review of the followingspecification in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of an interior rearview mirrorassembly in accordance with the present invention;

FIG. 2 is an exploded perspective view of the interior rearview mirrorassembly of FIG. 1;

FIG. 3 is an exploded perspective view of another interior rearviewmirror assembly in accordance with the present invention;

FIG. 4 is an exploded perspective view of another interior rearviewmirror assembly in accordance with the present invention;

FIG. 5 is an exploded perspective view of another interior rearviewmirror assembly in accordance with the present invention;

FIG. 6 is a perspective view of a reflective element assembly portion ofthe mirror assembly of the present invention, with the reflectiveelement removed to show additional details;

FIG. 7 is an opposite perspective view of the reflective elementassembly portion of FIG. 6;

FIG. 8 is a perspective view of a cap portion of the mirror assembly ofFIG. 5;

FIG. 9 is a perspective view of a cap portion and circuit boards of FIG.5, as assembled;

FIG. 10 is a rear perspective view of another interior rearview mirrorassembly of the present invention;

FIG. 11 is a rear elevation of another interior rearview mirror assemblyof the present invention;

FIG. 12 is a front elevation of an interior rearview mirror assembly,having directional heading or compass display in accordance with thepresent invention;

FIGS. 13A-D are enlarged elevations of customized compass displays inaccordance with the present invention;

FIG. 14 is a front elevation of another interior rearview mirrorassembly, showing another compass display in accordance with the presentinvention;

FIG. 15 is a front elevation of another interior rearview mirrorassembly, showing another compass display in accordance with the presentinvention;

FIG. 16 is a front elevation of another interior rearview mirrorassembly, showing another compass display in accordance with the presentinvention

FIG. 17 is a front elevation of another interior rearview mirrorassembly having a compass and temperature display;

FIG. 18 is a front elevation of another interior rearview mirrorassembly, having a garage door opening system display and user inputs inaccordance with the present invention;

FIG. 19 is a front elevation of another interior rearview mirrorassembly, having a compass display and a tire pressure monitoring systemdisplay in accordance with the present invention;

FIG. 20 is a front elevation of another interior rearview mirrorassembly, having a tire pressure monitoring system display in accordancewith the present invention;

FIG. 21 is an enlarged front elevation of another tire pressuremonitoring system display in accordance with the present invention;

FIG. 22 is a front elevation of another interior rearview mirrorassembly, having a telematics module and display in accordance with thepresent invention;

FIG. 23 is a front elevation of another interior rearview mirrorassembly, having a telematics module and display in accordance with thepresent invention;

FIG. 24 is a perspective view of a cap portion for an interior rearviewmirror assembly in accordance with the present invention;

FIG. 25 is an enlarged perspective view of a light actuator of the capportion of FIG. 24;

FIG. 26 is a perspective view of another cap portion of the presentinvention;

FIG. 27 is an upper perspective view of an interior rearview mirrorassembly of the present invention, with microphones positioned along anupper cap portion;

FIG. 28 is a sectional view of an interior rearview mirror assemblyhaving a battery in accordance with the present invention;

FIG. 29 is an exploded perspective view of another interior rearviewmirror assembly in accordance with the present invention;

FIG. 30 is a rear perspective view of the mounting assembly of themirror assembly of FIG. 29;

FIG. 31 is a sectional view of the mounting arm and mount of FIG. 30;

FIG. 32 is a rear perspective view of another mounting assembly of thepresent invention;

FIG. 33A is a sectional view of an electrochromic reflective elementassembly portion in accordance with the present invention;

FIG. 33B is a sectional view of another electrochromic reflectiveelement assembly portion in accordance with the present invention;

FIG. 33C is a sectional view of a prismatic reflective element assemblyportion and rear mirror casing cap portion in accordance with thepresent invention;

FIG. 34 is a perspective view of another interior rearview mirrorassembly and a windshield accessory module in accordance with thepresent invention;

FIGS. 35A-D are perspective views of different accessory modules of thepresent invention;

FIG. 36 is a sectional view of an electro-optic reflective elementassembly;

FIG. 37A is a plan view of the third surface of a rear substrate for anexterior electro-optic reflective element assembly in accordance withthe present invention; and

FIG. 37B is a plan view of the second surface of a front substrate forthe exterior electro-optic reflective element assembly.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings and the illustrative embodiments depictedtherein, an interior rearview mirror assembly or modular prismaticrearview mirror assembly 10 for a vehicle includes a reflective elementassembly portion 13 including a mirror holder 12 and a reflectiveelement 14 (FIG. 1) positioned at and at least partially within themirror holder and/or bezel portion, that preferably is molded from apolyolefin material, such as a polypropylene material or the like.Mirror assembly 10 includes a plastic molded cap or cap portion 16,preferably molded from an ABS material, an engineering resin material,such as a filled or unfilled nylon material, or the like (and may beintegrally molded with metallic or ceramic materials or inserts or thelike to provide mechanical bracing and enhanced structural rigidity).Cap portion 16 is mountable or attachable to a rear portion or openportion 12 a of mirror holder 12, and may include an accessory orfeature or the like, such as a printed circuit board 18 having anelectronic accessory or circuitry thereon or integrated therein orattached thereto. Cap portion 16 may be snapped or otherwise mounted toor attached to the open rear portion 12 a of mirror holder 12 to installor back-load the printed circuit board and/or accessory within themirror holder 12 of mirror assembly 10. Cap portion 16 may be detachablymounted or attached to the mirror holder, such as via accessible detentsor snaps or the like, and may be removable or detachable from the rearportion of the mirror holder, such as for service or replacement of thecap portion or one or more accessories of the cap portion.

Various cap portions of the present invention may be provided withdifferent options or accessories, and may be selected to mount to orattach to a universal or common mirror holder to form different mirrorassemblies having different content. The present invention thus allowsan automobile manufacturer to order or purchase common or standardmirror holders or reflective element assembly portions and different orcustom cap portions and to assemble the mirror assembly with the desiredcap portion and content at the vehicle assembly plant. The automobilemanufacturer may even choose to purchase the mirror holders (which mayinclude the reflective element) from one source and the cap portionsfrom another source, and may complete the mirror assembly at the vehicleassembly plant or at another facility, such as a mirror assembly plantor the like. The present invention thus allows an automobilemanufacturer to order or purchase the mirror holder and reflectiveelement (and maybe the toggle assembly and mounting assembly as well,such as shown in FIGS. 6 and 7) from a mirror specialist, and the capportions and accessories (such as shown in FIG. 9) from an electronicsspecialist. The cap portion may snap or otherwise attach to the mirrorholder to complete the assembly of the rearview mirror assembly.

Because the cap portion or portions may be purchased separately, thepresent invention lends itself to aftermarket applications or todealership or consumer customizations/personalizations, where a capportion having the desired accessories or appearance or design may bepurchased and installed to a mirror holder to alter or upgrade themirror assembly of the vehicle. It is envisioned that such an upgradecould be made to a base mirror that does not originally include anyelectronic accessories, whereby the cap portion could provide electricalcontent to the mirror assembly. In such applications, the cap portionmay connect to a power source or the like of the vehicle (such as via awire or cable that extends between the mirror assembly and the headlineror an accessory module of the vehicle when the mirror assembly isinstalled in the vehicle) or the cap portion may include a battery orself-contained power source to provide power to the accessories andcircuitry contained within the cap portion, such as discussed below withrespect to FIG. 28.

In an aftermarket application, cap portions may be provided asaftermarket cap portions, and a consumer may purchase a desired capportion, which may have desired content or features and/or may have adesired color or texture or appearance or the like, and may readilyremove the existing cap portion from the mirror of their vehicle andreplace it with the new cap portion. For example, the cap portion and/orthe mirror holder may have snaps or clasps that may retain the capportion and the mirror holder together, but that may release or detachsuch that the cap portion may be detachable from the mirror holder by auser. The cap portion may be pulled or detached from the mirror holderand a new cap portion may be pressed or snapped into place on the mirrorholder to provide the vehicle owner with the new cap portion having thedesired content or functions or features and/or the desired appearanceor the like, as discussed in detail below.

Reflective element 14 may comprise a prismatic reflective element havinga wedge shaped prism with a reflective coating on its rear surface, suchas described in U.S. Pat. Nos. 6,318,870; 5,327,288; 4,948,242;4,826,289; 4,436,371 and 4,435,042; and/or U.S. patent application Ser.No. 10/709,434, filed May 5, 2004, now U.S. Pat. No. 7,420,756; and/orU.S. provisional application Ser. No. 60/525,952, filed Nov. 26, 2003,which are all hereby incorporated herein by reference. Reflectiveelement 14 may include one or more displays which may be laser-etched orotherwise formed thereon, such as via an appliqué or the like on thesurface of the reflective element or such as a display on demand type ofdisplay (discussed below). The display may include one or more displayelements, such as illumination sources, such as vacuum fluorescent (VF)elements, liquid crystal displays (LCDs), light emitting diodes (LEDs),such as inorganic LEDs or organic light emitting diodes (OLEDs),electroluminescent (EL) elements or the like. Optionally, the prismaticreflective element may comprise a display on demand or transflectiveprismatic element (such as described in PCT Application No.PCT/US03/29776, filed Sep. 19, 2003 and published Apr. 1, 2004 asInternational Publication No. WO 2004/026633; and/or U.S. provisionalapplication Ser. No. 60/525,952, filed Nov. 26, 2003, which are allhereby incorporated herein by reference) so that the displays areviewable through the reflective element, while the display area stillfunctions to substantially reflect light, in order to provide agenerally uniform prismatic reflective element even in the areas thathave display elements positioned behind the reflective element.

For example, as shown in FIGS. 1-5 and 12, prismatic reflective element14 may include a compass display 14 a and/or other display, such as apassenger side inflatable restraint status display 14 b (FIGS. 2-4) orthe like, formed or etched on the reflective element. For example, thecompass display 14 a may include ports 15 a, such as icons, charactersor directional headings (N, S, E, W), etched or formed in the reflectivecoating of the reflective element (such as via removing the reflectivecoating of the reflective element to form a desired port or icon orcharacter and/or such as by utilizing aspects described in U.S. Pat. No.4,882,565, issued to Gallmeyer, which is hereby incorporated herein byreference) to allow light from corresponding illumination sources orelements 19 a (such as light emitting diodes or the like) to passthrough the reflective element to illuminate or back light theappropriate port or icon or heading character for viewing by the driveror occupant of the vehicle, such as similar to the compass systemsdisclosed in U.S. patent application Ser. No. 10/456,599, filed Jun. 6,2003, now U.S. Pat. No. 7,004,593, which is hereby incorporated hereinby reference in its entirety, and as discussed below.

As shown in FIG. 5, the reflective element 14 may include ananti-scatter film or sheet or tape 14 c applied over its rear surface.The tape 14 c may be adhered or otherwise attached to the rear surfaceof the reflective element so as to limit shattering or scattering of themirror glass if the vehicle is involved in an accident. Also, thereflective element 14 may include a display appliqué 14 d that may beadhered or applied to the rear surface of the reflective element in thegeneral region of the display 14 a (and/or at the region of otherdisplays at the reflective element). The display appliqué 14 d maycomprise a diffusing element or material, such as a white diffusingmaterial with a smoked front or the like, to diffuse the light emittedby the display elements so that a person viewing the display 14 a willnot readily discern the individual lighting elements or filaments, butwill view substantially uniform illumination provided by the lightingelements or filaments.

Interior rearview mirror assembly 10 may include a toggle assembly 20and a mounting portion 22, which may be pivotally connected to toggleassembly 20 and mounted to the vehicle to provide pivotal movement ofthe mirror holder and reflective element relative to the vehicle. Toggleassembly 20 may include a toggle member 20 a, which may be actuated ormoved by a user to adjust the mirror holder and reflective elementrelative to the vehicle. Optionally, toggle member 20 a may comprise asoft touch surface or portion, such as disclosed in U.S. Pat. Nos.6,318,870 and 6,349,450, which are hereby incorporated herein byreference. Such a soft touch surface or portion preferably comprises asoft touch material (such as a thermoplastic elastomer or other similarthermoplastic materials, such as Santoprene or the like), preferablyhaving a Shore A durometer value of less than about 110 Shore A, morepreferably less than about 90 Shore A, and most preferably less thanabout 70 Shore A, that may be molded over a rigid or harder material orstructure, such as by utilizing aspects described in U.S. Pat. No.6,349,450, which is hereby incorporated herein by reference. The toggleassembly or the mirror holder may also include a pivot joint or pivotelement 20 b, such as a socket and/or ball member, molded or formedthereon or attached or mounted thereto, in order to provide pivotalmovement or adjustment of the mirror assembly relative to the mountingarm or portion. The mounting portion 22 may be mounted to the vehicle,such as to an interior surface of the vehicle windshield or to a headerportion of the vehicle or the like, via any mounting arm and button orany other mounting arrangement or construction, such as the typesdisclosed in U.S. Pat. Nos. 6,499,850; 6,318,870; 6,315,421; 6,227,675;5,671,996; 5,813,745; 5,673,994; 5,820,097; 5,708,410; 5,680,263;5,582,383; 5,576,687; 5,555,136; 5,521,760; 5,330,149; 5,100,095;5,058,851; 4,930,742; 4,936,533; 4,436,371; 4,524,941; 4,435,042 and/or4,646,210; and/or PCT Publication No. WO 03/095269, published Nov. 20,2003; and/or PCT Publication No. WO 03/099614, published Dec. 4, 2003,which are hereby incorporated by reference herein, without affecting thescope of the present invention. Optionally, the mirror assembly may bemounted to the vehicle portion (such as to the windshield or headlinerof the vehicle) via a substantially plastic or all plastic double ballmounting arrangement, such as described in U.S. Pat. No. 6,318,870and/or U.S. patent application Ser. No. 10/032,401, filed Dec. 20, 2001,now U.S. Pat. No. 6,877,709, which are hereby incorporated herein byreference. The mounting arrangement may be configured to provide forwiring to the mirror assembly through the mounting arrangement and to orinto the mirror assembly, without affecting the scope of the presentinvention.

During assembly of the reflective element assembly portion, the mountingmember or arm may be inserted into the socket portion at the reflectiveelement assembly portion (such as at the reflective element or at abacking plate of the reflective element or at a toggle assembly of themirror assembly or the like) via an automated device or machine or by arobot. The automatic device or machine may be used to attach or snap thefront end of the mounting member to the socket portion at the reflectiveelement.

Optionally, the mirror assembly may provide or include an automatic flipprismatic reflective element, such as described in U.S. Pat. Nos.6,717,712; 6,568,414 and/or 6,382,806, which are hereby incorporatedherein by reference. Because the circuit board and any display elementspositioned thereon is/are generally fixedly secured to the cap portion,which in turn is generally fixedly secured to or relative to the mirrorholder and reflective element, the circuit board and display elementsmove with the reflective element during adjustment of the mirror, suchthat there is substantially no change in the juxtapositioning/alignmentof the lighting or display through the prismatic reflective element.

Mirror holder 12 of interior rearview mirror assembly 10 preferablycomprises a unitary or one-piece mirror holder (preferably molded from athermoplastic resin, such as a polyolefin, such as polypropylene or thelike), which may be molded or otherwise formed with a bezel portion 12 bintegrally formed therewith, and which receives the prismatic reflectiveelement therein. As shown in FIGS. 6 and 7, the toggle assembly 20 andmounting portion 22 may be attached to the mirror holder/bezel portion12, preferably while the mirror holder is still warm and pliable.Although not shown in FIGS. 6 and 7, the reflective element 14 may beattached to or inserted into the mirror holder/bezel portion 12 ataround the same time to form a mirror holder assembly that may beattached to the appropriate or desired cap portion, as discussed below.The reflective element and molded portion or bezel portion thus maydefine a reflective element assembly portion 13 of the mirror assembly10. The toggle assembly 20 and the prismatic reflective element 14 thusmay be secured into place (such as by snapping together) at or in themirror holder 12 while the molded mirror holder (preferably the freshlymolded mirror holder) is still warm and pliable, such as disclosed inU.S. Pat. No. 4,436,371, issued to Wood et al., which is herebyincorporated herein by reference. When the molded mirror holder(preferably the freshly molded mirror holder and thus just exiting theinjection molding press, or alternately, and less desirably, a heatedmirror holder having been heated, such as in an oven or the like, tomake the mirror holder warm and pliable) cools and shrinks, the mirrorholder grips around the toggle assembly and the prismatic reflectiveelement to retain the toggle assembly and the reflective element in thereflective element assembly portion.

The material of the mirror holder or bezel portion, and/or of thereflective element assembly portion in totality, may be selected to havea desired linear mold shrinkage or tool shrinkage factor to provide thedesired amount or degree of shrinkage as the mirror holder cools andshrinks around the reflective element to secure the reflective elementat the mirror holder or bezel portion. For example, at least the bezelmaterial, and preferably the reflective element assembly portion intotality, may have a linear mold shrinkage or tool shrinkage factor ofpreferably at least about 0.01 cm/cm or about 1%, and more preferably atleast about 0.015 cm/cm or about 1.5%. For example, a UV stabilized,general purpose black polypropylene polymeric molding resinous material,such as is commercially available from Huntsman Corp. of Houston, Tex.under the trade name REXENE 17C9A, and having a tool shrinkage factor of0.018 cm/cm or 1.8%, may be a suitable material for the bezel portion inthat it provides a desired degree of shrinkage around the reflectiveelement as the material cools, and after formation of the mirror holderor bezel portion by molding in an injection molding operation and/orafter heating an already-molded mirror holder or bezel portion to anelevated temperature (such as greater than 70 degrees Celsius orhigher), in order to sufficiently retain the reflective element at thebezel portion.

The linear mold shrinkage or tool shrinkage factors, as known in thematerial science arts, are determinable by test standards, such as bytest standards set by the American Society for Testing and Materials(ASTM), such as the ASTM D 955 (Standard Test Method of MeasuringShrinkage from Mold Dimensions of Thermoplastics), which is herebyincorporated herein by reference, or such as by ISO 294-4, which ishereby incorporated herein by reference. The test measures the shrinkagefrom the mold cavity to the molded dimensions of thermoplastics whenmolded by compression or injection molding processes with specifiedprocess conditions or parameters.

As shown in FIGS. 2 and 3, the rear portion 12 a of mirror holder 12 mayhave openings or apertures 12 c formed therethrough at either or bothsides of the toggle assembly to allow for insertion of the accessory oraccessories supported by the corresponding cap portions, as discussedbelow. Optionally, and as shown in FIGS. 4-7, the mirror holder 12′ maybe substantially open for a unitary cap portion 16″ to attach at, asalso discussed below.

After the mirror holder and reflective element are assembled together,and maybe after the mirror holder has cooled and shrunk (such as inapplications where the reflective element/mirror holder assembly isprovided or shipped from a different location than where the cap portionand electrical circuitry or electrical content are from), the capportion 16 may be attached or secured to the rear portion 12 a of mirrorholder 12 to complete the assembly of rearview mirror assembly 10. Incomparison to the bezel material, the material selected for the capportion need not have such shrinkage properties as described above,because the cap portion may be fabricated at and supplied from separateoperations, locations and/or facilities than the bezel portion. However,the cap portion may be fabricated at the same facility or location, butcould be made during a different operation and/or at a different time,without affecting the scope of the present invention. For example, thecap portion preferably is formed by injection molding of a polymericresinous material having a tool shrinkage factor of less than andpreferably substantially less than about 0.01 cm/cm or about 1%(although it may also have higher tool shrinkage factors, withoutaffecting the scope of the present invention), and preferably less thanapproximately 0.008 cm/cm or about 0.8%. This enables the provision inthe cap portion of material properties not readily deliverable by thehigher linear mold shrinkage or tool shrinkage factor materials used forthe bezel portion.

For example, the cap portion material may have a higher heatstability/higher heat deflection property/higher flexural moduluscompared to the reflective element assembly portion, in order tomaintain any accessories or elements mechanically attached thereto ortherein. Also, the cap portion material may be selected to provide ahigher structural strength if desired. For example, the cap portionmaterial may comprise a high temperature ABS material, such as availablefrom BASF or others under the trade name TERLURAN® GRADE-HH106, whichhas a tool shrinkage factor of around 0.006 cm/cm or 0.6%, or othersuitable materials, such as Nylon and preferably a filled Nylon materialor the like. Such a material may also provide structural characteristicsthat are suitable for supporting accessories or the like. For example,the cap portion material may desirably have a heat deflectiontemperature under load of 0.45 MPa of greater than approximately 100degrees Celsius (and more desirably, greater than approximately 110degrees Celsius and most desirably greater than approximately 115degrees Celsius), as determined by standard testing, such as by ASTM 648or ISO 75-1/-2 (which are hereby incorporated herein by reference) orthe like. Such testing may determine the temperature at which anarbitrary deformation occurs when a specimen of the material issubjected to an arbitrary set of testing conditions or parameters.

The tool shrinkage factor of the resinous material molded to form thecap portion thus is preferably less than the tool shrinkage factor ofthe resinous material molded to form the bezel portion of the reflectiveelement assembly portion. Also, the flexural modulus of the materialthat forms the cap portion may preferably be greater than the flexuralmodulus of the material that forms the mirror holder or bezel portion.Also, the material that forms the cap portion may preferably have ahigher heat deflection temperature (such as may be determined bystandard testing, such as ASTM D-790, which is hereby incorporatedherein by reference) than the material that forms the bezel portion ormirror holder. Such standardized testing may determine the flexuralproperties or flexural strength of the material via bending or breakingof specimens of the material in accordance with the appropriate testparameters. Desirably, although the polymeric resinous materials usedfor the bezel portion and the cap portion may be different, the portionsmay have similar exterior finishes and/or textures. Alternatively,however, the portions may have different finishes and/or textures or thelike as discussed below, without affecting the scope of the presentinvention.

Optionally, and as described above, the mirror holder and reflectiveelement assembly portion may be packaged and moved to another facilityand/or the cap portion may be received from another facility to completethe mirror assembly. The appropriate or selected cap portion (with theappropriate associated electrical circuitry/accessory/content) may thenbe attached to the reflective element/mirror holder assembly, such as atthe vehicle assembly line, to assemble the mirror assembly forinstallation into the appropriate vehicle having the optional content ofthe mirror assembly, as discussed below. The modular mirror assembly ofthe present invention thus facilitates assembly of the reflectiveelement assembly portion and of the cap portion at different assemblylocations, whereby the two portions may be joined or assembled togetherat a different location, such as at the vehicle assembly plant, tocomplete the mirror assembly. The cap portion may attach to thereflective element assembly portion via a snap together connection orother type of connection, and may removably or detachably attach, sothat the cap portion may be removed from the reflective element assemblyportion if desired. However, the cap portion may alternatively benon-detachably attached, such as by adhesive attachment or by heatstaking or by ultrasonic welding or the like, without affecting thescope of the present invention. The cap portion may attach to thereflective element assembly portion via any manner, such as, forexample, utilizing aspects described in U.S. Pat. No. 6,402,331, whichis hereby incorporated herein by reference. Thus, the present inventionencompasses customization/selection of material properties for the capportion to be different from material properties selected for thereflective element assembly portion so that decorative finishes and/orfunctional properties may be customized/delivered to be the same ordifferent for one or both of the portions.

Optionally, one or more accessory modules or blocks (such as discussedbelow) may be attached to or inserted or plugged into the cap portionand/or mirror assembly, such as at the vehicle assembly line, to providea desired or selected or customized optional feature or accessory to themirror assembly. The accessory module may insert or attach to the mirrorassembly or cap portion utilizing aspects described in U.S. Pat. Nos.6,672,744; 6,402,331; 6,386,742 and 6,124,886, and/or U.S. patentapplication Ser. No. 10/739,766, filed Dec. 18, 2003, now U.S. Pat. No.6,877,888, which are hereby incorporated herein by reference. Theaccessory module may include circuitry and display elements and userinputs, and may plug into the cap portion or mirror assembly in a mannerwhereby mechanical and electrical connections are preferablysimultaneously made as the module is inserted into the cap portion ormirror assembly, such as by utilizing aspects described in U.S. Pat. No.6,669,267, and/or U.S. patent application Ser. No. 10/727,731, filedDec. 3, 2003, now U.S. Pat. No. 6,969,101, which are hereby incorporatedherein by reference. The mirror assemblies thus may be customized toparticular work orders or selected options at the vehicle assembly linevia insertion or attachment of the appropriate accessory module, suchthat the cap portion and the reflective element assembly portion maycomprises common or universal components for two or more options offeredfor the particular mirror assembly or vehicle application.

The modular mirror assembly of the present invention thus may providefully assembled mirror assemblies to a vehicle assembly plant and line,where the cap portion and selected content are attached to thereflective element assembly portion at a remote location, such thatdifferent mirror assemblies are provided for different options orapplications. Optionally, the modular mirror assembly may provide auniversal or common reflective element assembly portion to a vehicleassembly plant, and a selected cap portion (with the appropriate ordesired or selected optional content) may be attached to the reflectiveelement assembly portion at the vehicle assembly line to customize themirror assembly for the particular selected option or application.Optionally, the modular mirror assembly of the present invention mayprovide a universal reflective element assembly portion and a partiallyor substantially universal (at least universal as to two or moreselectable options) cap portion, whereby the selected accessory modulemay be inserted into or attached to the cap portion and/or mirrorassembly at the vehicle assembly line to complete the mirror assemblyand to provide the desired or selected option or feature to the mirrorassembly.

As shown in FIG. 2, cap portion 16 may comprise two separate capportions 16 a, 16 b, or a cap portion 16′ (FIG. 3) may have two capportions 16 a′, 16 b′ joined together by a connecting portion or wirechannel 16 c. One or both of the cap portions 16 a, 16 b may have anaccessory or circuit board 18 a, 18 b attached thereto. The circuitboard or boards may snap or otherwise affix or secure to the cap portionor portions. As shown in FIG. 2, the cap portions may have retainers orpillars extending from an interior surface for retaining and supportingthe circuit board or boards thereon. Optionally, the cap portion maycomprise a unitary cap portion 16″ (FIGS. 4, 5, 8-11, 24 and 26)substantially covering the rear portion of the mirror holder (oppositethe reflective element) and receiving or supporting one or more printedcircuit boards thereon. The cap portion may receive the mounting portion22 between the side portions of the cap portion 16′ (FIG. 3) or throughan opening 25 a in the cap portion 16″ (FIGS. 4, 8-11, 24 and 26) as thecap portion is attached to the mirror holder. For example, the mountingportion 22 may be threaded through the opening 25 a in the cap portionas the cap portion is moved toward and into engagement with the bezelportion during the mirror assembly process. The mirror assemblies 10′and 10″ (with cap portions 16′ and 16″, respectively) may besubstantially similar to and may have substantially similar componentsand accessories as mirror assembly 10 (with cap portions 16 a, 16 b),such that a detailed description will not be repeated for the differentmirror assemblies. The common or similar components of the mirrorassemblies are referred to in FIGS. 2-11 with the same referencenumbers.

The cap portion 16 or portions 16 a, 16 b may be positioned at openings12 c of mirror holder 12 such that the accessories or circuitrysupported by the cap portions are positioned generally within mirrorholder 12. The cap portions may snap onto the rear portion 12 a ofmirror holder 12 and generally cover the openings 12 c in mirror holder12. Optionally, the unitary cap portion 16″ may snap onto or otherwisesecure to the mirror holder and generally cover or define the rearportion of the mirror assembly when so assembled. The cap portion orportions thus support the circuit board or circuit boards and associatedcircuitry and/or accessories at or within the mirror assembly.

Optionally, the circuit boards or accessories may be provided at, withinor on the cap portions at a cap portion manufacturing facility orelectrical accessory manufacturing facility, such that the cap portionand circuitry assemblies are provided as a unit to the mirror assemblyfacility or plant. The cap portion and circuitry units may then besnapped or otherwise affixed to the mirror holder or reflective elementassembly portion of an appropriate mirror assembly having features orcomponents or displays corresponding to the cap portion and circuitryunits, as discussed below. The assembly or back-loading of the capportions to the mirror holder and reflective element assembly portionthus may be performed remote from the molding tool for molding themirror holder, since the cap portions may be mounted to the mirrorholder after the mirror holder has cooled and shrunk.

Each cap portion may support one or more desired accessories or circuitboards for providing the desired feature to the mirror assembly. The capportions, and corresponding accessory or feature or electrical content,may be selected and attached to a universal or common mirror holder toprovide different features to the mirror depending on the optionsselected for a particular application or vehicle. Optionally, the capportions may be selected/configured to have accessoriescontained/supported therein to correspond to and be alignedwith/juxtapositioned with one or more displays of a particular orrespective reflective element secured in the common mirror holder and/ormay correspond with a particular mirror holder for applications wherethe accessory includes buttons or controls which may extend throughopenings or recesses in the mirror holder for access thereto by thedriver or occupant of the vehicle, as discussed in detail below.

The cap portion or cap portions may be snapped or otherwise secured tothe rear portion 12 a of mirror holder 12, such as generally at andcovering corresponding openings 12 c through the rear portion 12 a ofmirror holder 12. The opening or openings 12 c may be at either or bothsides of the toggle assembly and mounting portion of the mirrorassembly. The cap portion may snap over or otherwise interconnect withthe respective opening via a plurality of hooks or snap clasps (whichmay extend from the cap portion or the mirror holder) engaging aplurality of corresponding slots or the like at the other of the capportion and the mirror holder. The cap portion may be formed to providean exterior surface which may substantially match the exterior surfaceof the mirror holder to provide a finished appearance to the mirrorassembly when the cap portions are attached to the mirror holder andthus form the rear or back portion of the mirror holder and/or it mayprovide a contrast or distinctive aesthetic or functional appearance orfinish. The mirror holder and the cap portions may be formed of apolypropylene material or a talc-filled polypropylene material or thelike, or preferably the mirror holder is formed of a molded polyolefin,while the cap portion is formed of a molded engineering resin, such asABS or a Nylon or the like. Optionally, the cap portion may comprise ametallic material or may comprise a polymeric molding overcoated with ametallic layer or coating, and may have ribs or ripples to provideenhanced rigidity of the cap portion, without affecting the scope of thepresent invention.

Optionally, the cap portion may have a different color or texture (suchas a chrome or colored or textured surface or the like) than the mirrorholder or bezel portion to provide a two-tone configuration to themirror assembly. Optionally, the cap portion and/or the mirror holdermay have a decorative finish, and may be painted or plated, such aselectroplated or the like, or may have a film or an in mold film orcoating thereon to provide the desired surface to the cap portion and/orthe mirror holder. For example, the cap portion (or the mirror holder)may provide a contrast or accent color or may be chrome plated or may bebrushed aluminum or the like or may provide an angle variant color(where the perceived color may change depending on the viewing angle) ormay provide various colors or patterns or textures or the like as may bedesired by a consumer (for example, certain colors or patterns ortextures may be provided to target different demographics, such as fortargeting teenagers or other age groups or genders or the like).Optionally, the cap portion or bezel portion may have a fabric cover(such as, for example, leather or cloth or denim or other cover materialor the like) at and substantially over at least a portion or theentirety of its exterior surface to provide a desired appearance ortexture or the like. Optionally, the cap portion and/or the mirrorholder or bezel portion may have a soft touch surface, such as a softtouch surface and material similar to that described above (preferablyhaving a Shore A durometer value of less than about 110 Shore A, morepreferably less than about 90 Shore A, and most preferably less thanabout 70 Shore A) with respect to the toggle tab and/or similar to thetypes described in U.S. Pat. Nos. 6,318,870 and/or 6,349,450, which arehereby incorporated herein by reference. For example, either the mirrorholder or the cap portion may have such a soft touch surface independentof the other, or both may have such a soft touch surface or neither mayhave a soft touch surface. Although the cap portion may be finished witha metallized reflective finish, such as a chrome or chrome-platedfinish, the bezel portion desirably may not be chrome or chrome-platedor the like, in order to reduce reflections or glare at the bezelportion around the reflective element, and thus not be specularlyreflecting.

It is further envisioned that the cap portion or bezel of the interioror exterior mirror assembly may include a personalization element, suchas a logo or text or pattern or other indicia, thereon as desired by theconsumer to provide highly personalized and unique mirror assemblies forthe particular consumers that purchase the vehicles or the mirrorassemblies, such as described in U.S. provisional applications, Ser. No.60/553,842, filed Mar. 17, 2004; and Ser. No. 60/563,342, filed Apr. 19,2004, which are hereby incorporated herein by reference. For example,the cap portion may include a school logo and colors, such as, forexample, the letters “MSU” in green and white print/background, toprovide a desirable appearance to the personalized mirror assembly for aparticular consumer, such as, for example, a student or graduate ofMichigan State University. Optionally, the cap portion may include othertext or logos or brand names or other types of identifying indicia, suchas, for example, “FORD” to identify the vehicle manufacturer, or “TOMMYHILFIGER” to identify the vehicle owner's clothing preference or thelike, or other text or messages or images or trademarks or colors orpatterns or indicia or the like to provide a desired appearance oridentification or message or statement or advertisement or logo orsponsorship identification or style or brand identification on theinterior or exterior mirror assembly. The mirror assemblies may thus beassembled to have the desired or personalized cap portion with thedesired or personalized logo or color or message or indicia thereon toprovide the desired or personalized finish or appearance of the interioror exterior mirror assembly.

In an aftermarket application, various cap portions as described abovemay be provided as aftermarket interior or exterior mirror cap portions.A consumer may then purchase a desired cap portion, which may havedesired content or features and/or may have a desired color or textureor appearance or the like, and may readily remove the existing capportion from the interior or exterior mirror assembly of their vehicleand replace it with the new cap portion. For example, the cap portionand/or the mirror holder or reflective element assembly portion (such asthe mirror support arm for an interior rearview mirror assembly or amirror mount for an exterior rearview mirror assembly) may have snaps orclasps that may retain the cap portion and mirror holder/mount/bezeltogether, but that may release or detach such that the cap portion maybe detachable from the mirror assembly by a user/consumer. The capportion may be pulled or detached from the mirror assembly and a new capportion (with the desired content therein and/or personalized text orindicia or colors or the like thereon) may be pressed or snapped intoplace on the mirror assembly to provide the vehicle owner with the newcap portion having the desired content or functions or features and/orthe desired or personalized appearance or the like.

Optionally, the modular mirror assembly of the present invention mayprovide customizing of other visible or viewable portions of the mirrorassembly as well. For example, the flip tab or toggle tab 20 a (or arotary knob or the like depending on the type of toggle assembly of theparticular mirror assembly) may be removably attached to the toggleassembly, such that the tab may be selected or replaced as desired. Thetab may threadedly attach to a threaded stud or bolt or nut or the likeat the toggle assembly (or may detachably attach via other means, suchas snaps, twist-on connections, a bayonet connection or the like), suchthat a desired tab may be readily attached to the toggle assembly toprovide the desired tab for the mirror assembly. The selectable orreplaceable or customized toggle tabs may provide various styles, sizes,shapes, appearances, textures, touches/feels (such as a soft touchmaterial or the like), colors, patterns, indicia (such as logos or iconsor the like as described below with respect to the center port 15 c ofthe compass display 14 a in FIGS. 13A-D). The customer/consumer thus mayselect the desired toggle tab for attachment to the mirror assembly(such as a tab that matches or is associated with the selected capportion and/or bezel portion and/or reflective element ports (discussedbelow) or the like) to customize the mirror assembly. The customizationand selection or replacement of the toggle tab may occur at thereflective element assembly portion assembly plant or at the mirrorassembly plant or at the vehicle assembly plant or at the vehicledealership or at any other aftermarket facility or the like, withoutaffecting the scope of the present invention. The custom tab may thus beselected and attached or replaced at the mirror assembly to provide acustom appearance without having to retool or mold a different toggleassembly.

Optionally, the bezel portion 12 may be molded of a universal orstandard color, finish and/or material, such as a black plastic materialor black polypropylene or the like, and an outer rim portion orperimeter trim portion element may attach to a forward edge of the bezelportion (at the viewable side of the reflective element) to provide adesired appearance and/or functionality of the bezel portion of themirror assembly to the driver and passenger of the vehicle. The bezelportion 12 may be formed to have a recess or trough or lip or the likearound its perimeter portion (such as at 12 b in FIG. 2), and thedesired trim portion element may be selected and snapped to or pressedinto or otherwise received in/attached to the perimeter portion of thebezel portion to provide the desired appearance/functionality to themirror assembly. The attachable trim portion element may provide variousstyles, appearances, textures, touches/feels (such as a rubber orelastomeric material or soft touch material or the like), colors,patterns, indicia (such as logos, icons or the like as described belowwith respect to the center port 15 c of the compass display 14 a inFIGS. 13A-D). The customer thus may select the desired trim portionelement for attachment to the bezel portion of the mirror assembly (suchas a trim portion element that matches or is associated with theselected cap portion and/or toggle tab and/or reflective element ports(discussed below) or the like) to customize the mirror assembly. Thetrim portion element may be selected to provide a soft material or animpact absorbing material, and may have a Shore A durometer hardnessthat is less than that of the bezel portion or mirror holder. Thecustomization and selection or replacement of the trim portion elementmay occur at the reflective element assembly portion assembly plant orat the mirror assembly plant or at the vehicle assembly plant or at thevehicle dealership or at any other aftermarket facility or the like,without affecting the scope of the present invention. The bezel portionthus may be formed as a universal or common bezel portion, and theviewable rim of the bezel portion (such as around the perimeter of thereflective element and viewable by a driver of the vehicle when themirror is installed in the vehicle) may be selected or replaced toprovide the desired or customized appearance and/or feel of the mirrorassembly.

Optionally, the cap portion, or one of the cap portions, such as the capportion 16 b on the side of the mirror assembly, such as the side whichwill be toward the passenger side of the vehicle when the mirrorassembly is installed in the vehicle, may include an electricalconnector for connecting the accessory or circuit board or boards 18 a,18 b to a vehicle wiring harness or power source of the vehicle.Optionally, the circuit board 18 b at the cap portion may include amulti-pin connector 24 for connecting to a corresponding multi-pinconnector of the vehicle wire harness. In such applications, an opening(such as opening 25 b of cap portion 16″ in FIGS. 4, 5 and 8-11) ofsufficient size may be provided in the cap portion (or optionally in themirror holder) to allow the connector on the wire harness to inserttherethrough for connection to the connector on the circuit board 18 b.The circuit board 18 b or connector 24 may be substantially supported atthe cap portion to provide sufficient support of the connector when acorresponding connector of the wire harness is pushed into engagementwith connector 24.

For example, the cap portion or mirror holder may have a connectorformed therein, whereby the wire harness may then connect to or pluginto the connector at the rear of the mirror assembly. The connector maybe formed as a selected or appropriate connector (such as a six pin oreight pin connector or the like) depending on the accessories of the capportions. Optionally, the connector may be formed with an insert in themold or tool for forming the cap portion, such that an appropriateinsert may be placed in the mold or tool to form the desired orappropriate connector on that particular cap portion. In the illustratedembodiment of FIGS. 4, 5 and 8-11, the connector 24 of the circuit boardincludes a plurality of pins 24 a for connecting to a connector or plug,and the cap portion 16″ has an opening 25 b formed therethrough so thatthe connector or plug may readily connect to the circuit board, and maysnap or otherwise be fastened or secured thereto, such as via clasps orthe like at the plug and/or at the cap portion 16″.

In applications where both cap portions 16 a, 16 b support an accessoryor circuit board, the circuit board 18 a on the cap portion 16 a (or thecircuit board on one side of the unitary cap portion) opposite theconnector 24 may be connected to the other circuit board 18 b and/orconnector 24 via one or more connecting wires 26, in order to providepower and/or control to the accessory on cap portion 16 a. Theconnecting wire or wires 26 may extend between the cap portions 16 a, 16b within the mirror holder 12 or may extend along the rear surface ofthe mirror holder 12, without affecting the scope of the presentinvention. As shown in FIG. 3, cap portion 16′ of an interior rearviewmirror assembly 10′ may comprise a single cap portion having a wirechannel or connector 16 c extending between opposite end caps or endportions 16 a′, 16 b′. The connecting wire (not shown in FIG. 3) mayextend between the circuit boards 18 a, 18 b or accessories supported onthe end portions 16 a′, 16 b′ and may be routed within the wire channel16 c or between the channel 16 c and the rear portion 12 a of the mirrorholder 12. Optionally, and as shown in FIGS. 4, 5, 8-11, 24 and 26, amirror assembly 10″ may have the single or unitary cap portion 16″ inaccordance with the present invention, and a connecting wire between twocircuit boards or accessories may extend along the cap portion toelectrically connect the circuit boards or accessories together.

As shown in FIG. 2, printed circuit board 18 b may include circuitry 19for a compass display 14 a and/or other accessory display, such as apassenger side inflatable restraint display 14 b or the like, atreflective element 12. More particularly, circuit board 18 b may includecompass display circuitry 19 having a plurality of illumination sources19 a which are individually illuminated or illuminated in combination toproject illumination through respective openings in circuit board 18 bto illuminate one or more of the ports or direction characters 15 aetched or formed in reflective element 14, such as in the mannerdisclosed in U.S. patent application Ser. No. 10/456,599, filed Jun. 6,2003, now U.S. Pat. No. 7,004,593, which is hereby incorporated hereinby reference in its entirety. The compass display thus may be controlledor actuated by a microcontroller or microprocessor of the cap portion ofthe mirror assembly. The controller may drive or energize theillumination sources (such as light emitting diodes or the like)directly, without the need for additional display drivers. The directenergization of the illumination sources of the display thus avoids theneed for other controllers or drivers within the cap portion or themirror assembly or the vehicle.

When the cap portion 16 b (or cap portion 16″ or the like) and circuitboard 18 b are attached to or juxtaposed with the mirror holder 12,circuit board 18 b may be pressed or urged toward the rear surface ofreflective element 14 such that the illumination sources 19 a (such aslight emitting diodes or the like) at the circuit board may generallyalign with the appropriate ports or characters or icons formed in thereflective element 14, as discussed below. For example, and as bestshown in FIGS. 8 and 9, the cap portion may include guide members orposts 25 c for engaging corresponding guide members or tabs or holes ornotches or recesses 18 c of the circuit board for guiding the circuitboard into the appropriate position and orientation on the cap portionas the circuit board is attached or snapped to the cap portion. The capportion may then attach to the mirror holder/bezel portion viaengagement and guiding of corresponding tabs and holes and the like,which function to position the cap portion in the desired locationrelative to the bezel portion, such that the circuit board (and anyillumination devices or the like positioned thereon) is/are properlyaligned with any associated display ports or switches or the like at themirror holder/bezel portion/reflective element.

As shown in FIGS. 4 and 5, a seal or sealing member or layer 17 or thelike may be applied to the rear surface of reflective element 14 or tothe forward face 18 d of circuit board 18 b to substantially seal theinterface between the circuit board 18 b and the reflective element 14,in order to limit or substantially preclude light from one of theillumination sources from illuminating a port or character or icon atthe reflective element other than the respective port or character oricon aligned with that illumination source and opening. The seal 17 maycomprise an opaque material, and may comprise a white (or other color)silicone gasket or the like, to diffuse and/or reflect light. The seal17 may be at least partially and preferably substantially flexible orresilient to compress and seal against the reflective element and thecircuit board to limit or substantially preclude light leakage from oneillumination source to one of the other ports or characters of thedisplay.

The circuit board may also include a connecting wire 28 which mayconnect to a compass pod or module 30 or other accessory or accessorymodule or the like for communication of compass heading or controlinformation to the compass display circuitry 19 at the circuit board orfor communication of other control information between the accessorymodule and the circuit board of the cap portion. For example, theconnecting wire 28 may extend from the cap portion and the rear of themirror assembly to the compass module 30, which may be attached to themounting arm or mounting button of the mirror assembly or otherwisepositioned or mounted at or near the mirror assembly. Compass module 30may include the compass circuitry (which may include calibrationcircuitry, a microprocessor and the like) and magnetoresponsive compasssensors (such as magnetoresistive sensors, magneto-capacitive sensors,magnetoinductive sensors or the like or a flux gate sensor or the like),such as described in U.S. Pat. Nos. 6,513,252 and 5,802,727, and/or U.S.patent application Ser. No. 10/456,599, filed Jun. 6, 2003, now U.S.Pat. No. 7,004,593, which are hereby incorporated herein by reference intheir entireties. The compass pod may also include an ambient lightsensor, whereby the intensity of the compass display (and other displaysof the mirror assembly) may be adjusted in response to the detectedambient light levels. Optionally, the compass system may utilizeprinciples disclosed in U.S. Pat. Nos. 5,924,212; 4,862,594; 4,937,945;5,131,154; 5,255,442 and/or 5,632,092, which are hereby incorporatedherein by reference.

Although shown and described as having a separate compass pod that maymount to the mirror mounting portion of the mirror assembly that in turnmounts to the likes of a mirror mounting button on the windshield (suchas described in U.S. Pat. Nos. 6,648,478; 5,708,410 and/or 5,576,687,which are hereby incorporated herein by reference) to remain generallystationary, it is envisioned that a compass pod or module or compasscircuitry and sensors may be positioned in a post or arm of a singleball mounting arrangement such that the sensors and circuitry aregenerally fixedly positioned relative to the mounting button and thevehicle. A wire may be routed along the generally fixed mounting arm(via and through the single ball joint) and to the display elements orillumination sources, such as in a manner similar to that shown in FIG.34, or a wire may be routed along the mounting arm and through thesingle ball and into the mirror casing or a wire or conductor may berouted or positioned along the arm and ball in any other manner tocommunicate electrical signals and the like to the circuitry and/orillumination sources of the cap portion, without affecting the scope ofthe present invention. The wire may provide slack to allow for theadjustment and movement of the mirror holder/cap portion about thesingle arm to avoid pulling at the wire during adjustment of the mirror.

The compass circuitry 19 on circuit board 18 b may also include a buttonor switch or control or may be in communication with a button or control23 (FIGS. 8, 10 and 11), such as at the rear of the cap portion 16″ orat the rear of the mirror holder, for actuating a calibration or zonefunction of the compass circuitry. In the illustrated embodiment, thebutton 23 may include an inward protrusion 23 a (FIGS. 8 and 24) thatextends forwardly from the cap portion 16″ or inwardly toward the buttonor switch or control on the circuit board when the cap portion 16″ isattached to the circuit board. The button 23 may comprise a flexible tab23 b integrally formed with and extending partially along the capportion 16″. When a user presses at the button 23, the tab 23 b flexesand the protrusion 23 a is moved toward and urged against the button orswitch on the circuit board 18 b to actuate the switch to control oractivate/deactivate the associated function of the compass circuitry (orother circuitry or accessory or the like that may be associated with theswitch on the circuit board). Although shown and described as beingintegrally formed with the single cap portion 16″ in FIGS. 8, 10, 11 and24, the button/flexible tab or flip actuation tab member may beintegrally formed on one of the side cap portions 16 a, 16 b or endportions 16 a′, 16 b′ of cap portion 16′ or the like, or on other typesof casings or housings or the like, without affecting the scope of thepresent invention.

Optionally, an additional illumination source or lighting element may beprovided on the circuit board 18 b for projecting illumination through acorresponding port or icon or character 15 b formed on the reflectiveelement 14 to indicate that the compass system is in the calibrationmode or zone setting mode. Optionally, the calibration mode may beindicated by a light emitting diode (LED) at the center port 15 c of thedisplay. For example, a dual-color LED may be provided at the centerport, where illumination in one color (such as, for example, red)indicates that the compass system is in the calibration mode. Once thecompass system is calibrated, however, illumination may be provided inthe other color (such as, for example, blue). Thus, when the compasssystem is not in the calibration mode, the other color (such as blue)indication color may be provided. Optionally, the calibration mode couldbe indicated without a dedicated illumination source or light emittingdiode or the like (because such an indicator would be used very rarelyin the life of the part). For example, the center illumination source orLED (which may be activated to provide an anchor point or focal pointfor the display, as discussed below) may be flashed or otherwisemodulated or adjusted when the system is in the calibration mode, orother similar types of indication may be provided to convey to thedriver that the compass is in its calibration mode.

The circuit board 18 b may also have an ambient light sensor orphotocell (not shown) for detecting the ambient light level at themirror assembly, whereby the circuitry may adjust the intensity of thedisplay in response to the detected ambient light levels. Acorresponding opening in the mirror holder 12 or at the rear of the capportion 16 (such as opening 25 d in cap portion 16″ of FIGS. 8, 10 and11) may allow the ambient light sensor to detect the ambient lightlevels through the opening. The light sensor may alternately bepositioned at the compass pod or module 30, without affecting the scopeof the present invention.

The compass display 14 a (FIGS. 1-5 and 12) thus may include a pluralityof direction indicating ports 15 a (such as four such ports formed torepresent the cardinal directional points or “N”, “E”, “S” and “W” orthe like) and may include an additional port 15 b for a calibrationindicator or light source, such as described in U.S. patent applicationSer. No. 10/456,599, filed Jun. 6, 2003, now U.S. Pat. No. 7,004,593,which is hereby incorporated herein by reference in its entirety.Compass display 14 a may further include a center port 15 c etched orotherwise formed at a central region of the display 14 a. Center port 15c may provide an opening or port for a rearward facing photosensorpositioned at the circuit board to receive light therethrough todetermine the ambient light at or in the vehicle cabin (or a glaresensor for determining glare at the mirror assembly for controlling anexterior electrochromic mirror assembly or cell or the like as discussedbelow) when the mirror assembly is assembled and positioned in thevehicle, such as discussed below.

Optionally, center port 15 c may align with an illumination source orlight emitting diode at the circuit board to provide a visible centerindicator or central anchor or focal point at the central region of thedisplay 14 a such that a person may readily identify the center of thecompass display. For example, when one of the directional headingindicators at ports 15 a are illuminated or energized, the indicator orlight source at center port 15 c may also be energized to provide avisible central anchor point for a person to recognize as the centralregion of the display. The provision of an extra illumination source orport that is central to the rosette N-E-S-W indicia thus helps to serveas a reference point for the driver, in order to aid the driver'scognitive association of the cardinal direction point that is intendedto be communicated when any one (or combination of two) of the N, E, S,W icons or ports are illuminated.

Optionally, the light emitting diodes aligned with the directionalindicating ports 15 a may be one color, while the light emitting diodesat the central port 15 c and/or at the calibration indicating port 15 bmay be another color or colors. For example, the directional indicatingports 15 a may be illuminated or back lit via blue indicators or lightemitting diodes or the like, while the central port 15 c may beilluminated or back lit via a red or amber indicator or light emittingdiode or the like, so that a person viewing the compass display indarkened conditions may readily discern which indicator is indicative ofthe central region of the display and thus where the center of thedisplay is, such that the person may readily recognize which directionalindicating port is illuminated, without having to look to see whether itis an “N” or an “E” or the like.

Optionally, the center port may be illuminated whenever the vehicle ison or powered, in order to provide substantially continuous illuminationof the center port. Preferably, the center port is illuminated at alower light output intensity than that of the respective cardinal N, E,S, W ports, so as to serve as a subtle eye point, but not to be confusedwith an actual directional indication. For this reason, a color contrastas well as an intensity contrast may be desirable.

In such applications where the center port is illuminated or back lit,an ambient sensor may be positioned elsewhere in the mirror assembly,such as elsewhere in the cap portion, and may be a forwardly facingsensor (i.e. toward the windshield when the interior rearview mirrorassembly is normally mounted in the interior cabin of a vehicle) and mayreceive light through a port or opening 25 d in the cap portion.Alternatively, the ambient sensor may be facing downwardly or upwardlywhen installed in the vehicle, without affecting the scope of thepresent invention. The ambient sensor may be generally aligned with orjuxtaposed at the port or opening or may receive the ambient light via alight pipe or the like, without affecting the scope of the presentinvention.

Optionally, and with reference to FIGS. 13A-D, the center port 15 c ofthe compass display 14 a (or other port or display area of thereflective element) may provide a graphic depiction of a desired image,such as a logo of the vehicle manufacturer or other desired image. Forexample, the center port 15 c may be etched (such as by laser etching orablation or by sandblasting or the like) or otherwise formed to providethe letters “FORD” or may be etched or otherwise formed in a patternsimilar to the design or designs indicative of the manufacturer, such asthe Chevrolet “bowtie” or the like. Optionally, other designs orpatterns or text or logos or indicia or the like may be provided at thecenter port 15 c (or elsewhere on the reflective element) to provide adesired image or logo. In the illustrated embodiments of FIGS. 13A-D,the central port is formed to be indicative of the vehicle manufacturer,such as for Dodge (FIG. 13A), Honda (FIG. 13B) or Jeep (FIG. 13C), orSubaru (FIG. 13D). However, the central port may be formed to beindicative of other vehicle manufacturers or entities or sponsors orindicia or trademarks or emblems or signature items, or representationsof a certain political views, religious beliefs, tribal affiliations,community ties, collegiate affiliations, allegiances and/or advocacy(such as, for example, a “peace” sign or other symbol or text or thelike) or other views, affiliations, beliefs, etc., or other custom portsor icons may be formed elsewhere on the reflective element to conveyother information or logos or the like, without affecting the scope ofthe present invention.

The desired image or logo may be indicative of the vehicle manufacturer,or may be selected by the user or vehicle owner to provide a customizedinterior rearview mirror assembly, such as described above with respectto the different logos or colors or textures or appearances ortouch/feel provided on the cap portion or bezel portion of the mirrorassembly, without affecting the scope of the present invention. Forexample, a person may select the logo or mascot of their alma mater tobe etched at the center of the compass display (or elsewhere on thereflective element) to customize the mirror assembly for that particularperson or owner. The customized or selected port may be at the centralport of the compass display or may at or incorporated into anotherdisplay at the reflective element or may be elsewhere at the reflectiveelement and separate from any other information display, withoutaffecting the scope of the present invention. Optionally, the lightsource or indicator positioned at the circuit board behind the customport may be selected to match the color that may be typically associatedwith the selected logo, such as a green or red or blue indicator orlight emitting diode or the like for the school color or the like. Otherforms of customized logos or indicia or the like may be etched orotherwise formed at the reflective element, without affecting the scopeof the present invention.

Optionally, and with reference to FIGS. 14-16, an interior rearviewmirror assembly 10′″ may include an intuitive heading instructional iconelement or display 14 a′ at the reflective element 14′, such as thetypes described in U.S. provisional application Ser. No. 60/553,517,filed Mar. 16, 2004, which is hereby incorporated herein by reference.The compass display 14 a′ may be associated with or controlled oradjusted by a compass system and/or a navigational system, such as acompass and/or navigational system of the types described in U.S. Pat.Nos. 6,678,614; 6,477,464; 5,924,212; 4,862,594; 4,937,945; 5,131,154;5,255,442 and/or 5,632,092, and/or U.S. patent applications, Ser. No.10/456,599, filed Jun. 6, 2003, now U.S. Pat. No. 7,004,593; Ser. No.10/645,762, filed Aug. 20, 2003, now U.S. Pat. No. 7,167,796; and Ser.No. 10/422,378, filed Apr. 24, 2003, now U.S. Pat. No. 6,946,978; and/orPCT Application No. PCT/US03/40611, filed Dec. 19, 2003 and publishedJul. 15, 2004 as International Publication No. WO 2004/058540, which areall hereby incorporated herein by reference.

Display 14 a′ includes a plurality of characters or icons or letters 15a (such as N, E, S, W as shown in FIGS. 14-16) formed or etched in thereflective coating or layer of the reflective element 14′ and includesan arrow or direction pointer 15 d at each of the characters 15 a. Thedisplay 14 a′ may also include a central port 15 c through thereflective coating or layer reflective element 14′ behind which may bepositioned an illumination source as described above or a glare sensor,such as a photo sensor or the like, such as a glare sensor and/or anambient light sensor and electrochromic automatic dimming circuitrydescribed in U.S. Pat. Nos. 4,793,690 and 5,193,029, and U.S. patentapplication Ser. No. 10/456,599, filed Jun. 6, 2003, now U.S. Pat. No.7,004,593, which are all hereby incorporated herein by reference. Thearrows of direction pointers may point generally upward when the mirrorassembly is mounted in the vehicle with the reflective element facinggenerally rearward and opposite to the direction of forward travel ofthe vehicle. The arrows or pointers thus may be representative of thedirection of forward travel of the vehicle. As shown in FIGS. 14-16, thedirection pointers of display 14 a′ may comprise generally triangularshaped icons or pointers 15 d positioned outward from the characters 15a and opposite the characters from the center or port 15 c of thedisplay (such as shown in FIG. 14), or the direction pointers of thedisplay may comprise arrows 15 d′ positioned next to the characters 15 a(such as shown in FIG. 15), or the direction pointers of the display maycomprise arrows 15 d″ positioned inward of the characters 15 a andbetween the respective characters and the center or port 15 c (such asshown in FIG. 16).

The compass/navigation system may be operable to energize one or moreillumination sources positioned at and rearward of a respective one ofthe characters 15 a and corresponding direction pointer 15 d toilluminate or back light the respective character and direction pointer.For example, the compass/navigation system may be operable to illuminateor back light a particular character and adjacent direction pointer toindicate to an occupant of the vehicle the direction that the vehicle iscurrently heading. For example, if the character “W” and the arrow ordirection pointer next to the “W” are illuminated, then the displayindicates that the vehicle is heading west. The intuitive headinginstructional icon element or display thus may provide reinforcement toa viewer that when the character (such as “W” or other character) isilluminated, it is done so to indicate that the vehicle is traveling inthe direction (such as west or other direction) indicated by thecharacter. This is reinforced by the illumination of the correspondingarrow or direction pointer that points upward so as to be representativeof pointing in the direction of forward travel of the vehicle. A personviewing the display thus will not misinterpret the illumination of thecharacters to be indicative of a driving or turning instruction (such asan instruction to turn the vehicle right or east to follow a programmedroute) in connection with the navigation system.

Optionally, the display may function as a display for providing both anindication of the directional heading of the vehicle and an indicationof which direction the vehicle should be turned in order to follow aprogrammed route or path. For example, only a particular directionpointer may be illuminated or back lit to indicate that the vehicle isheading in the direction indicated by the non-lit character next to theilluminated pointer, while a different character (separate from theilluminated pointer) may be illuminated or back lit to indicate that thevehicle is to be turned in that direction to follow a programmed routeto a desired destination. The compass/navigation system and display thusmay clearly display to a driver of the vehicle which direction thevehicle is heading at that time via the directional arrows, while thecompass/navigation system and display may also be operable to providedriving or turning instructions to a driver of the vehicle to instructthe driver as to which direction the driver is to turn to follow aparticular route to a desired destination. For example, thecompass/navigation system may be associated with a global positioningsystem and/or telematics system of the vehicle, and may generate anddisplay driving instructions to the driver of the vehicle as the vehicleis driven along a generated route, such as by utilizing aspectsdescribed in U.S. Pat. Nos. 6,678,614 and 6,477,464, and/or U.S. patentapplication Ser. No. 10/456,599, filed Jun. 6, 2003, now U.S. Pat. No.7,004,593; Ser. No. 10/645,762, filed Aug. 20, 2003, now U.S. Pat. No.7,167,796; and Ser. No. 10/422,378, filed Apr. 24, 2003, now U.S. Pat.No. 6,946,978; and/or PCT Application No. PCT/US03/40611, filed Dec. 19,2003 and published Jul. 15, 2004 as International Publication No. WO2004/058540, which are all hereby incorporated herein by reference.

During operation, the compass/navigation system thus may be operable toenergize an illumination source positioned at and rearward of/behind arespective one of the characters to provide a driving instruction to thedriver of the vehicle that is separate from the directional headingindication also provided by illumination or back lighting of the arrowsor pointers of the display. For example, if the vehicle is headinggenerally west, the compass/navigation system may illuminate or backlight the arrow next to the “W” to indicate to the driver of the vehiclethat the vehicle is traveling generally in that direction. If theprogrammed route for the vehicle involves an upcoming right turn onto agenerally northbound road, the compass/navigation system may thenilluminate or back light the letter “N” to indicate to the driver of thevehicle that the driver should turn the vehicle to head north.

It is further envisioned that the illuminated character may be alteredor adjusted as the vehicle gets closer to the turning point orintersection, such as by flashing the illumination source orintensifying the illumination source or changing the color of theillumination as the vehicle approaches the desired or appropriateturning point or intersection. It is also further envisioned that arrowspointing sideways may be provided at one or more of the characters ofthe display (or elsewhere at the display), and the appropriate arrow maybe illuminated or back lit to indicate that the driver is to turn rightor left to stay on the desired course or route. In such an embodiment,illumination or back lighting of the character may be indicative of thedirectional heading of the vehicle, while illumination or back lightingof the arrows may be indicative of the driving instructions to thedriver of the vehicle.

The intuitive display elements thus provide a clear indication as towhich direction the vehicle is presently traveling by providing adirectional heading arrow or pointer at each of the compass headingcharacters. The driver of the vehicle thus will not likely becomeconfused as to the meaning of the illuminated characters or letters. Thecompass/navigation system and display of the present invention also mayprovide point-to-point driving instructions and the present directionalheading of the vehicle with the same display or displayicons/characters.

Optionally, the compass display may include a temperature display oranother type of information display with an LED array at or near thecompass display ports or icons. One or more control buttons or inputs(such as at the rear side of the mirror assembly) may be provided toallow the driver or occupant of the vehicle to select or actuate thecalibration or zone or temperature display functions. The circuit boardmay be in communication with a temperature sensor or system, such as viaa connecting wire or the like, to receive an electronic signalindicative of the temperature to be displayed. Optionally, the capportions and circuit boards may support or provide a compass and/ortemperature display utilizing vacuum fluorescent displays and filters todisplay the compass heading and/or temperature via two or morecharacters or letters or numbers. For example, and as shown in FIG. 17,a compass heading display 32 a and a temperature display 32 b may beprovided or formed at a display region 32 c of a reflective element 14″of a mirror assembly. The displays may comprise alphanumeric charactersor the like to convey the directional heading information andtemperature information to the driver of the vehicle.

Optionally, the circuit board may also or otherwise include circuitryfor another accessory and/or display at the reflective element. Theother display circuitry may illuminate or project information viailluminating ports or icons or characters or the like which are etchedor otherwise formed on the reflective element, such as in a similarmanner as described above. The display circuitry and associated controlcircuitry may be positioned at the circuit board. Optionally, some ofthe circuitry may be positioned outside of the mirror assembly, such asat an accessory pod or module, and may be in communication with thecircuitry of the circuit board via a connecting wire or the like, suchas described above with respect to the compass circuitry.

Optionally, the illumination sources utilized to back light orilluminate the display icons or characters may emit a desired color oflight, such as a blue colored or tinted light or other color as may bedesired. In many mirror applications, a blue light is typicallypreferred because it provides high visibility of the display during highlighting or daytime conditions, but may not be as favorable during lowlight or nighttime conditions. Optionally, a control or multiplexer maybe operable to change the color of the display in response to an ambientlight sensor or the like. For example, the control may deactivate a blueillumination source and activate an amber or red illumination source (orother color) when the ambient light level drops to a threshold level.The nighttime color may be selected to provide enhanced viewing of thedisplays and may be selected to generally match the lighting colorscheme or signature color of the particular vehicle in which the displayis implemented. Optionally, the colors may be ramped on and off, suchthat in intermediate lighting conditions, both colors may be providedand mixed, in order to provide a gradual change from one color to thenext as the ambient light levels increase or decrease. Optionally, thecontrol may activate a second illumination source (a nighttimeillumination source that may be directed toward and through the sameport as a daytime illumination source) in parallel with the daytimeillumination source (such as a blue illumination source), which mayremain activated so that the colors of the illumination sources aremixed during nighttime or darkened conditions.

As also shown in FIGS. 2-5, one of the circuit boards, such as circuitboard 18 a supported by cap portion 16 a (FIG. 2) or circuit board 18 asupported by cap portion 16″ (FIGS. 4 and 5) or the like, may include anaccessory or circuitry 21 and associated manual inputs or controls orbuttons 21 a for providing manual control of the circuitry or accessory21. For example, circuitry 21 may comprise circuitry for a garage dooropening device or system, such as a universal garage door opener or thelike. With reference to FIG. 2, one or more buttons 21 a (and/or one ormore lights or illuminated buttons or controls) may extend or projectfrom circuitry 21 and may extend at least partially through or may beaccessible through corresponding openings or holes 21 b in mirror holder12. Optionally, and as shown in FIGS. 4 and 5, one or more buttons 21 a′may be provided at a circuit board 18 a, and may be positioned orreceived in a recessed area 21 b′ along the bezel portion or mirrorholder 12 and/or in a recessed area 25 e along the cap portion 16″, suchthat the buttons may be secured in place between the mirror holder andcap portion when the cap portion is attached to or secured to the mirrorholder. The buttons 21 a, 21 a′ may be readily accessible by the driveror occupant of the vehicle to actuate or control the circuitry 21, suchas to actuate a transmitting device to open or close a garage door, suchas utilizing the principles disclosed in U.S. Pat. Nos. 6,396,408;6,362,771; 5,798,688 and 5,479,155; and/or U.S. patent application Ser.No. 10/770,736, filed Feb. 3, 2004, now U.S. Pat. No. 7,023,322, whichare hereby incorporated herein by reference.

Optionally, and as shown in FIG. 18, a garage door opener display 34 maybe provided at the reflective element of the mirror assembly fordisplaying a Homelink® icon (or other icon or indicia indicative of sucha system) at the buttons or inputs 21 a, 21 a′ for the garage dooropener system, such as might be useful as an indicator to assist a userwhen training or operating in a learning mode of a trainable garage dooropener (such as by intermittently illuminating ormodulating/flashing/blinking an LED or the like behind a Homelink® iconor the like when in the learning mode) and/or as an indicator forcompany brand promotion/feature illustration promotion, such as byconstantly illuminating the LED or the like, such as when a trainablegarage door opener is not in the training or learning mode. The garagedoor opener display 34 may have an illumination source (such as a lightemitting diode or the like) that may be activated or energized to backlight or otherwise illuminate the display as desired. The displayelements and circuitry and user inputs may be added to or attached tothe cap portion as a module so that the desired feature or content maybe readily added to a corresponding cap portion to provide the desiredfeature or content to the appropriate mirror assembly.

Because it is desirable that the mirror holder be a universal mirrorholder for mirror assemblies having various accessories or noaccessories, it is envisioned that the openings 21 b in mirror holder 12for the input controls 21 a of accessory 21 (and/or other openings forother user inputs or buttons or switches or the like for otheraccessories or the like) may be formed in the mirror holder via insertspositioned in the mirror holder mold or tool for mirror holders whichrequire such openings. The inserts may be removed from the tool toprovide molding of a mirror holder without such openings forapplications where no such accessory and associated controls or buttonsis selected. Similarly, the recessed regions 21 b′ in the mirror holderand/or the cap portion may be formed via inserts placed in the moldsduring the forming of the mirror holder or cap portion. The differentmirror holders may thus be molded or formed using the same tool, yet mayreceive different cap portions having or supporting differentaccessories or features.

In the illustrated embodiment, the buttons 21 a are positioned at themirror assembly so that user actuation of the buttons requires agenerally vertical upward force (when the mirror assembly is installedin the vehicle) to move the button or input upwardly to actuate theelectronic switch. Optionally, however, the buttons or inputs may bepositioned at the mirror assembly so that actuation of the button orswitch or input may be accomplished by a generally horizontal force ormovement, such as a generally horizontal force toward the mirrorassembly or in the direction of travel of the vehicle. For example, theuser inputs may be positioned in a gondola or pod or attachment orextension of the cap portion that extends outwardly (such as downwardlyor upwardly or sidewardly) from the cap portion so as to be viewable andreadily accessible by the driver of the vehicle. The user inputs may bepositioned within the gondola or pod so that pressing the user inputsgenerally horizontally actuates the switch (such as an electronic switchat the printed circuit board within the cap portion of the mirrorassembly). The cap portion or attachment may include mechanical elementsor structure for mechanically translating the generally horizontalmovement of the input to a generally vertical actuation of an electronicswitch, or the electronic switch may be oriented at the circuit board tobe responsive to the generally horizontal actuation movement, withoutaffecting the scope of the present invention. Preferably, such gondolaor pod may extend upward or toward the passenger side of the mirrorassembly (when the mirror assembly is installed in the vehicle) to limitor reduce any interference with the forward field of view of the driverof the vehicle.

Although shown and described as having buttons such as shown in FIGS.2-5 and 10, it is envisioned that the mirror assembly may includebuttons or inputs of the types described in U.S. provisionalapplications, Ser. No. 60/553,517, filed Mar. 16, 2004; and Ser. No.60/535,559, filed Jan. 9, 2004, which are hereby incorporated herein byreference. For example, the buttons may be integrally molded in the capportion or bezel, or the buttons may extend downward through openings inthe cap portion or bezel or between the cap portion and bezel when thecap portion is attached to the bezel, without affecting the scope of thepresent invention.

Optionally, the cap portions and circuit boards may support one or moreother accessories and/or corresponding displays at or within the mirrorholder, such as a tire pressure monitoring system and display 36, 36′(FIGS. 19-21), whereby the display may indicate when a tire pressure hasdropped below a set or preselected tire pressure. For example, aparticular light source may be energized or activated to back light orilluminate an icon 36 a indicative of one of the tires of the vehiclewhen the pressure in that tire drops below the threshold tire pressure.The individual light sources may be individually energized, such as in asimilar manner as the directional heading indicators discussed aboveand/or described in U.S. patent application Ser. No. 10/456,599, filedJun. 6, 2003, now U.S. Pat. No. 7,004,593, which is hereby incorporatedherein by reference. The display may include an iconistic display thatmay be laser etched or otherwise formed on the reflective element (suchas described above), and may provide for illumination (via one or moreillumination sources at the circuit board of one of the cap portions) ofone or more icons 36 a representative of a particular tire of thevehicle. Optionally, and as shown in FIG. 21, the tire pressure display36′ may be printed on a screen and placed at and generally aligned witha window formed in the reflective layer of the prismatic reflectiveelement, without affecting the scope of the present invention. Thedisplay may further provide for illumination of an additional icon orcharacter 36 b or may provide a different color illumination when apuncture is detected at one of the tires of the vehicle. Optionally, thetire pressure monitoring display 36′ may include a digital display 36 c(or other type of character or alphanumeric display) for indicating thetire pressure of one of the tires. The tire pressure monitoring systemmay utilize principles disclosed in U.S. Pat. Nos. 6,124,647; 6,294,989;6,445,287; 6,472,979 and/or 6,731,205, which are hereby incorporatedherein by reference.

The tire pressure display thus may be controlled or actuated by amicrocontroller or microprocessor of the cap portion of the mirrorassembly. The controller may drive or energize the illumination sources(such as light emitting diodes or the like) directly, without the needfor additional display drivers. The direct energization of theillumination sources of the display thus avoids the need for othercontrollers or drivers within the mirror assembly or the vehicle. Thetire pressure monitoring system display 36, 36′ may utilize aspects ofthe compass display disclosed in U.S. patent application Ser. No.10/456,599, filed Jun. 6, 2003, now U.S. Pat. No. 7,004,593, which ishereby incorporated herein by reference in its entirety.

Optionally, the cap portion may include circuitry and user inputsassociated with a telematics system, such as ONSTAR® or the like. Forexample, a circuit board may include circuitry for the telematics systemand may be attached to or mounted to a cap portion, such as a circuitboard similar to circuit board 18 a described above. The cap portionand/or mirror holder may include a recess or opening for one or moreuser inputs to be positioned when the mirror assembly is assembled, sothat the user inputs may be readily accessible by a driver of thevehicle when the mirror assembly is installed in the vehicle. As shownin FIG. 22, the user inputs or buttons 38 may extend along a lowerportion of the mirror assembly and may be readily viewable andaccessible at the lower portion of the mirror assembly by a driver ofthe vehicle. The user inputs 38 may comprise a keypad or the like thatis positioned within corresponding notches or recesses along the opposedor mating edges of the mirror holder and the cap portion, such asdescribed above with respect to user inputs 21 a′ of FIGS. 4 and 5. Atelematics display 40 may be etched or otherwise formed in thereflective element 14 to indicate to a user the function of the userinputs 38. The display 40 may include one or more icons or images orcharacters 40 a or the like that may be etched or formed in thereflective element and backlit by respective illumination sources. Theillumination source or sources may be activated during low ambientlighting conditions (such as dusk or night, such as when ambientlighting is less than, for example, about 200 lux) to illuminate thedisplay 40 so a user can see the function of the user inputs (which mayalso be illuminated or backlit or the like) during low lightingconditions, such as at nighttime. Optionally, individual illuminationsources may be provided at each icon or port 40 a to independentlyilluminate or back light the respective icon, such as in response toactuation of a respective one of the user inputs (such as in a manner asdescribed above with respect to the individual directional icons of thecompass display). Optionally, and with reference to FIG. 23, the display40′ may be positioned at a window 42 of the reflective element 14 andmay be viewable through the reflective element window.

The cap portions of the present invention thus may provide a desiredcontent, such as a garage door opening system and respective user inputsor a telematics feature and respective user inputs, to a particularmirror assembly. The desired system may be provided to the cap portionas a module, such as a garage door opening system module (which mayinclude the transmitter and circuitry and user inputs) or a telematicsmodule (which may include the circuitry and user inputs and displayelements), and the module may be attached to or snapped to or mounted tothe cap portion, such as at a cap portion assembly facility or at thevehicle assembly facility. Although shown as a garage door openingsystem module or a telematics module, clearly, the cap portion mayinclude or incorporate other modules or displays or the like, such as,for example, a passenger side air bag status display (typically on thelower passenger side corner or area of the reflective element) or otherdisplays, or a rear-facing sensor (which may align with an opening orport or window formed in the reflective element when the cap portion isattached to the mirror holder), or other types of displays or systems ormodules, without affecting the scope of the present invention.Optionally, the user inputs or buttons or switches or the like may bepositioned in the cap portion or in the bezel portion (or between thecap portion and bezel portion), or the cap portion may include aneyebrow portion or gondola portion or underbrow portion or chin portionor attachment (that may extend or protrude partially outward and/orpartially around the bezel portion, and that may extend upwardly ordownwardly or sidewardly therefrom) in which the inputs may bepositioned, such that the inputs are contained at or in the cap portionand readily viewable and/or accessible at a desired location around thebezel portion.

The desired cap portion (with the desired features or content) may bereadily attached to a common or universal mirror holder (which mayinclude the reflective element and toggle and mounting assembly, whichmay be assembled at a mirror holder assembly facility) to assemble themirror assembly, such as at a mirror assembly facility. The mirrorholder may be adapted to partially receive the user inputs therein,and/or the reflective element contained in the mirror holder may have aparticular display or displays formed thereon. The display icons orports or windows formed in the reflective layer of the reflectiveelement may generally align with the respective display elements orillumination sources of the circuitry within the cap portion when thecap portion is attached to the mirror assembly, such as described abovewith respect to the compass display. In applications where differentmodules may be provided that provide different display information atthe reflective element, the reflective element may be selected to havethe appropriate ports or icons or the like that correspond with theparticular module, or the reflective element may have a window orwindows formed in the desired or appropriate locations or may comprise atransflective prismatic reflective element (such as described in PCTApplication No. PCT/US03/29776, filed Sep. 19, 2003 and published Apr.1, 2004 as International Publication No. WO 2004/026633; and/or U.S.provisional application Ser. No. 60/525,952, filed Nov. 26, 2003, whichare hereby incorporated herein by reference), such that the displayelements (which may be illuminated alphanumeric characters or icons orindicia or the like) of the modules may be viewable through thereflective element to view the information being displayed by thedisplay elements. The present invention thus provides for various mirrorassemblies having different features or electronic content, whileproviding common or universal mirror holders and cap portions, wheredifferent circuitry or circuit boards or modules may be attached to thecap portion to provide the desired content to the mirror assembly.

Optionally, the cap portion or portions and circuit board or boards maysupport one or more other accessories or features at or within themirror holder, such as one or more electrical or electronic devices oraccessories. For example, and as can be seen in FIGS. 24-26,illumination sources or lights, such as map reading lights 46 or one ormore other lights or illumination sources (which may be positioned at oraligned with openings formed in the bottom of the mirror holder todirect illumination generally downward to illuminate the console of thevehicle), such as illumination sources of the types disclosed in U.S.Pat. Nos. 6,690,268; 5,938,321; 5,813,745; 5,820,245; 5,673,994;5,649,756; 5,178,448; 5,671,996; 4,646,210; 4,733,336; 4,807,096;6,042,253 and/or 5,669,698, and/or U.S. patent applications, Ser. No.10/054,633, filed Jan. 22, 2002, now U.S. Pat. No. 7,195,381; and/orSer. No. 10/745,056, filed Dec. 22, 2003, now U.S. Pat. No. 6,971,775;and/or U.S. provisional application Ser. No. 60/500,858, filed Sep. 5,2003, which are hereby incorporated herein by reference, may be includedwith the cap portion 16″. The illumination source or sources 46 may beattachable to or positionable at or molded into the cap portion and mayconnect to a circuit board 47 of the cap portion 16″. The illuminationsources and/or the circuit board may be connected to one or more buttonsor inputs 48 for activating and deactivating the illumination sources.

Optionally, and with reference to FIG. 26, the circuitry 47 a maycomprise a stamped circuit that is molded into and/or along the capportion, with the electrical connections between the lights and buttonsand power source being made via stamped connectors or terminals moldedinto the cap portion (such as terminals of the type described in U.S.Pat. No. 6,227,689, which is hereby incorporated herein by reference)and extending between the lights 46 and/or inputs/buttons (not shown inFIG. 26) and/or the power source/circuit board 47. The illuminationsources 46 and inputs 48 may be positioned at recesses in and along aforward edge or portion of cap portion 16″ and may be partially receivedin corresponding recesses along the rearward edge of the correspondingmirror holder to secure the illumination sources and buttons at themirror assembly.

As best shown in FIGS. 24 and 25, the light actuators or buttons 48 maycomprise a push button actuator having a user actuating portion 48 a ata lower end of a body portion 48 b. The actuator 48 may comprise anyknown switch or button assembly, or may be of the type described in U.S.patent application Ser. No. 10/447,641, filed May 29, 2003, now U.S.Pat. No. 6,953,905, which is hereby incorporated herein by reference.Body portion 48 b may be slidably mounted to or positioned in or at thecap portion 16″ and may slide between an activated position, where theswitch closes the circuit to activate the light source, and adeactivated position, where the switch opens the circuit to deactivatethe light source. The actuator 48 includes a torsional spring 49 wrappedaround a shaft 48 c protruding from body portion 48 b. One end 49 a ofthe spring 49 engages a stop 50 a extending from the cap portion 16″,while the other end 49 b is movable around a detent 50 b as the switchbody 48 b is moved between the activated and deactivated positions. Forexample, when the switch is in the lowered or deactivated position, thespring may bias the switch downward (which may open the circuit) viaengagement with the stop 50 a. When the switch is pressed upward, theend 49 b may move upward around the detent 50 b and may rest within arecess 50 c of the detent 50 b when the switch is released to retain theswitch in the raised or activated position (which may close thecircuit). When the switch is again pressed upward by a user, the end 49b may move upward and out from the recess 50 c and may move downwardaround the detent 50 b as the switch is urged or moved downward inresponse to the biasing forces of the spring 49. The actuator 48 thusprovides a low cost actuating device that only has a few components and,thus, is less costly and less complicated and more durable than manymultiple component switches in use today.

Optionally, the cap portion may provide circuitry or power for a lightor illumination source, such as a map reading light or the like, and adesired or appropriate lighting capsule or module (including the lightsource and user input or button or switch) may be plugged into themirror assembly (such as described in U.S. patent applications, Ser. No.10/054,633, filed Jan. 22, 2002, now U.S. Pat. No. 7,195,381; and Ser.No. 10/745,056, filed Dec. 22, 2003, now U.S. Pat. No. 6,971,775, whichare hereby incorporated herein by reference). The circuit board of thecap portion may include prongs or connectors or the like at a lowerportion of the circuit board, and the lighting capsule may be insertedthrough an opening in the cap portion and/or mirror holder and mayengage and connect to the prongs or connectors to electrically connectthe light to the circuit board. The lights thus may be readily insertedinto or connected to the circuit board of the cap portion if desired orappropriate to provide the desired feature or content to the cap portionand the mirror assembly.

Optionally, the mirror assembly may include a white light emittingdiode, or a cluster of LEDs may be provided, as a map/reading light orlight module. Optionally, the cap portion or bezel portion may includeillumination sources, such as light emitting diodes or the like, thatmay be embedded in the rim of the bezel portion or the lower portion ofthe cap portion to emit or project illumination toward the desired areaof the vehicle cabin. The illumination sources may be switched onlocally, such as via user inputs or switches or buttons as describedabove, or may be activated/deactivated/controlled by a control or systemremote from the mirror assembly, such as via a vehicle electronic orcommunication system, and may be connected via a hard wire or viavarious protocols or nodes, such as Bluetooth, SCP, UBP, J1850, CANJ2284, Fire Wire 1394, MOST, LIN and/or the like, depending on theparticular application.

Optionally, the illumination sources may comprise modular light sources,and may comprise one or more incandescent light sources or lightemitting diodes or the like, such as described in U.S. patentapplications, Ser. No. 10/054,633, filed Jan. 22, 2002, now U.S. Pat.No. 7,195,381; and Ser. No. 10/745,056, filed Dec. 22, 2003, now U.S.Pat. No. 6,971,775, which are hereby incorporated herein by reference.Optionally, the light emitting diodes may be operable to individuallyemit illumination in different colors as desired, so as to provide moodlighting or the like. The illumination sources may be controlled via auser input at the lights or a separate or remote control device, such asa vehicle electronic or communication system, and may be connected via ahard wire or via various protocols or nodes, such as Bluetooth, SCP,UBP, J1850, CAN J2284, Fire Wire 1394, MOST, LIN and/or the like (whichmay also control the exterior mirror or mirrors of the vehicle), and mayprovide ramped activation and/or deactivation to provide theater likelighting or the like if desired.

Optionally, the cap portion may include or incorporate or receive othermodules as selected or desired to customize the mirror assembly. Forexample, the cap portion and/or reflective element assembly portion mayreceive a microphone array module, a garage door opening system module,a telematics user access button/input module, and/or the like. Themodules may be provided at the vehicle assembly plant or at the mirrorassembly plant, and may be inserted or plugged into the cap portion ormirror assembly to provide the desired content to the mirror assembly.The modules and the cap portion may include connectors that provide bothelectrical and mechanical connection so that the modules areelectrically connected to the appropriate circuitry as they are insertedor received into or snapped to or attached to the cap portion. Anoperator at the vehicle assembly plant thus may readily connect theappropriate module to the cap portion or to the mirror assembly toprovide the desired content for that particular mirror assembly. For abase mirror that may not include such content, a blank module or plugmay be inserted into or attached to the cap portion or mirror assembly,so as to fill or conceal any opening in the mirror assembly thatotherwise may receive an electronic module or accessory. The modules mayalso be readily removed and replaced to ease repair and replacement ofthe accessory or circuitry, and to ease replacement or changeover to adifferent accessory or module, if a different option is desired, such asan aftermarket module or the like.

Optionally, the cap portion or portions and the circuit board or boardsof the present invention may also or otherwise include otheraccessories, such as microphones 51 (such as shown in FIGS. 5 and/or27). The microphones may comprise analog microphones or digitalmicrophones or the like, and may be positioned at or aligned with one ormore openings formed in the top and/or bottom of the cap portion or themirror holder. The microphones, such as microphones of the typesdisclosed in U.S. Pat. Nos. 6,243,003; 6,278,377 and/or 6,420,975,and/or in PCT Application No. PCT/US03/308877, filed Oct. 1, 2003 andpublished Apr. 15, 2004 as International Publication No. WO 2004/032568,may be provided for interfacing with a vehicle telematics system or thelike. Optionally, the cap portion or portions and the circuit board orboards may also or otherwise include other accessories, such as atelematics system, speakers, antennas, including global positioningsystem (GPS) or cellular phone antennas, such as disclosed in U.S. Pat.No. 5,971,552, a communication module, such as disclosed in U.S. Pat.No. 5,798,688, a voice recorder, a blind spot detection system, such asdisclosed in U.S. Pat. Nos. 5,929,786 and/or 5,786,772, and/or U.S.patent applications, Ser. No. 10/427,051, filed Apr. 30, 2003, now U.S.Pat. No. 7,038,577; and Ser. No. 10/209,173, filed Jul. 31, 2002, nowU.S. Pat. No. 6,882,287, transmitters and/or receivers, such as for agarage door opener or a vehicle door unlocking system or the like (suchas a remote keyless entry system), a digital network, such as describedin U.S. Pat. No. 5,798,575, a high/low headlamp controller, such as acamera-based headlamp control, such as disclosed in U.S. Pat. Nos.5,796,094 and/or 5,715,093, a memory mirror system, such as disclosed inU.S. Pat. No. 5,796,176, a hands-free phone attachment, a video devicefor internal cabin surveillance (such as for sleep detection or driverdrowsiness detection or the like) and/or video telephone function, suchas disclosed in U.S. Pat. Nos. 5,760,962 and/or 5,877,897, a remotekeyless entry receiver, a seat occupancy detector, a remote startercontrol, a yaw sensor, a clock, a carbon monoxide detector, statusdisplays, such as displays that display a status of a door of thevehicle, a transmission selection (4 wd/2 wd or traction control (TCS)or the like), an antilock braking system, a road condition (that maywarn the driver of icy road conditions) and/or the like, a tripcomputer, a tire pressure monitoring system (TPMS) receiver (such asdescribed in U.S. Pat. Nos. 6,124,647; 6,294,989; 6,445,287; 6,472,979and/or 6,731,205), an ONSTAR® system and/or the like (with all of theabove-referenced patents and PCT and U.S. patent applications beingcommonly assigned, and with the disclosures of the referenced patentsand patent applications being hereby incorporated herein by reference intheir entireties). The accessory or accessories may be positioned at oron the cap portions and thus positioned at or within the mirror holderand may be included on or integrated in a printed circuit boardpositioned within the mirror holder.

Optionally, the cap portion or portions of the present invention mayinclude one or more attachments, such as attachments of the typesdescribed in U.S. Pat. Nos. 6,690,268 and/or 6,428,172, which are herebyincorporated herein by reference. The attachment or attachments, such asa pen holder or display screen or the like, may be incorporated into thecap portion or may be removably attached to the cap portion and, thus,may be removable if not desired for the particular mirror application,without affecting the scope of the present invention. The desiredattachment may be selected for the particular application of the capportion and mirror assembly, and may provide additional features to thecap portion and mirror assembly as may be desired or selected for theparticular mirror application.

Optionally, the cap portion or portions may include a conversationmirror that may flip up or out from the cap portion to allow the driverof the vehicle to view a person in the rear seat (such as a child in therear seat) to see and talk to the person in the rear seat without havingto adjust the reflective element of the mirror assembly. Theconversation mirror may be pulled out when desired or may be springloaded to pop up or out when actuated or depressed, or may beelectronically controlled to extend out from the cap portion when aninput is actuated, without affecting the scope of the present invention.

Optionally, a blind spot detection or side object detection system orcircuitry and corresponding display or indicator may be provided on oneof the cap portions and on the reflective element for indicating to thedriver or occupant of the vehicle that another vehicle may be in a laneadjacent to the subject vehicle. The indicator may comprise anyiconistic type of display which may indicate that another vehicle hasbeen detected and/or that the subject vehicle is changing lanes towardthe detected object or vehicle. The side object detection and warningsystem may utilize the principles disclosed in U.S. patent applications,Ser. No. 10/427,051, filed Apr. 30, 2003, now U.S. Pat. No. 7,038,577;and Ser. No. 10/209,173, filed Jul. 31, 2002, now U.S. Pat. No.6,882,287, which are hereby incorporated herein by reference.

Optionally, the side object detection system may be operable to detectobjects or other vehicles at one or both sides of the subject vehicleand to detect and identify a lane marker or lane markers at one or bothsides of the vehicle, such as disclosed in U.S. patent application Ser.No. 10/427,051, filed Apr. 30, 2003, incorporated above. The side objectdetection system may be further operable to provide a visible and/oraudible warning to the driver of the subject vehicle in response to thedetection of another object or vehicle at a side of the subject vehicleand in response to the position or movement of the subject vehiclerelative to the lane markers. The use of lane marker detectionintegrated with such side object detection systems can be used to reducefalse positives (where the system detects a vehicle in the adjacent lanewhen there is no vehicle in the adjacent lane) significantly and enablelonger distances of detection, which in turn improves response time forsystem warnings from high speed target vehicles. In known orconventional side object detection systems, the systems do not tracklane markings. Known radar systems are incapable of lane tracking due tothe nature of the technology, and conventional vision systems do notcurrently include this functionality. This forces the detection zone ofsuch known side object detection systems to be static or non-changingregardless of any curvature in the road, and does not allow for higherwarning functionality based on the lane position of the subject vehicle.

It is envisioned that the side object detection system (which may havecomponents and/or circuitry on a cap portion or portions of the interiorrearview mirror assembly, or on or at or in the mirror assembly or on orat or in an accessory module or pod mounted to or positioned at or nearthe mirror assembly or positioned elsewhere in the vehicle) may utilizelane marking detection and recognition to allow the side objectdetection system to determine or adjust a detection zone or target zoneor area based on the lane markings of the adjacent lane. Such lanemarking detection may accommodate a non-linear detection zone when thesubject vehicle is turning or on a curve. This may provide a longerdetection distance because non-linear lanes may cause false positives ina static detection zone, whereas a dynamic zone may facilitate a betterarea of interest at greater distances, since it may avoid trackingtrailing vehicles (such as in the same lane as the subject vehicle) onsharp curves. Such a side object detection system may also allow higherhuman/machine interface (HMI) processing.

Known side object detection systems may be specified to warn when avehicle is in the blind spot or will be in a short amount of time. Thismay force the system to warn the driver of a detected object even when adriver is not intending to make a lane change toward the detectedobject. This can be a source of annoyance to the driver, and itemphasizes the effect of false positives from detection ofinfrastructure, shadows, miscellaneous road clutter and the like.However, if the side object detection system requires the abovecondition or detection and also requires a close proximity to ormovement toward the lane markers or adjacent lane (i.e. the subjectvehicle is moving toward the lane markers and thus toward the adjacentlane) prior to providing a warning, then the system may only providesuch a warning when actual danger is present (i.e. the subject vehicleis changing lanes toward an adjacent lane which is occupied by adetected vehicle or object).

Such a side object detection system may provide a large reduction offalse positives over current side object detection systems, and thewarning may thus represent a heightened level of risk for the currentmaneuver, instead of a heightened level of risk for a potentialmaneuver. The side object detection system thus may reduce annoyance,improve perceived reliability, and improve overall detection distances,which in turn may improve the predictive nature of the system to reducelatencies based on human response. The side object detection system, orcircuitry and/or display of the side object detection system, may beincorporated into one or more cap portions mounted at the interiorrearview mirror assembly, or may be incorporated into the rearviewmirror assembly or an accessory module or pod positioned at or near therearview mirror assembly. The display may be at the reflective elementof the mirror assembly and may be an iconistic display of the subjectvehicle and a detected object adjacent to the subject vehicle, or anyother type of display, and may provide an audible signal to the driverof the vehicle, without affecting the scope of the present invention.

Optionally, the cap portion or portions may include a display element,such as a video display element or the like, that may slide out or flipup or down from the cap portion to provide a video screen that isviewable by the driver of the vehicle, such as a video display screen ofthe type described in PCT Application No. PCT/US03/40611, filed Dec. 19,2003 and published Jul. 15, 2004 as International Publication No. WO2004/058540, which is hereby incorporated herein by reference. The videodisplay screen may be operable to display information to the driver ofthe vehicle, and may be incorporated into or may be in communicationwith a vision system or imaging system of the vehicle, such as arearwardly directed vehicle vision system utilizing principles disclosedin U.S. Pat. Nos. 5,550,677; 5,760,962; 5,670,935; 6,201,642 and/or6,717,610, and/or in U.S. patent application Ser. No. 10/010,862, filedDec. 6, 2001, now U.S. Pat. No. 6,757,109, which are hereby incorporatedherein by reference, a trailer hitching aid or tow check system, such asthe type disclosed in U.S. patent application Ser. No. 10/418,486, filedApr. 18, 2003, now U.S. Pat. No. 7,005,974, which is hereby incorporatedherein by reference, a cabin viewing device or system, such as a babyviewing or rear seat viewing camera or device or system or the like,such as disclosed in U.S. Pat. Nos. 5,877,897 and 6,690,268, which arehereby incorporated herein by reference, a video communication device orsystem, such as disclosed in U.S. Pat. No. 6,690,268, which is herebyincorporated herein by reference, and/or the like. Optionally, the videodisplay screen may also or otherwise serve as a screen for a navigationsystem of the vehicle or the like, such as a GPS-based navigationsystem, such as is known in the automotive art.

Optionally, the mirror assembly may include a heating device or elementfor heating the display element or the area around the display element.At low temperatures, it may be desirable to heat the display element,such as a liquid crystal display (LCD) element or the like (or such as avideo screen display or illuminated display or the like), in order toenhance the performance and response of the display element in such lowtemperatures or cold conditions or environments. The display element maycomprise any type of display element or light emitting element, such asa vacuum fluorescent (VF) display element, a light emitting diode (LED)display element (such as an inorganic LED display element or an organiclight emitting diode (OLED) display element or a high intensity, highefficiency LED display element, such as disclosed in U.S. Pat. Nos.6,690,268 and 6,428,172 and in U.S. patent application Ser. No.10/054,633, filed Jan. 22, 2002, now U.S. Pat. No. 7,195,381, which arehereby incorporated herein by reference), a multi-pixel, dot-matrixliquid crystal display element, an electroluminescent display element, abacklit display element, such as a back lit iconistic display (such asdisclosed in U.S. Pat. Nos. 6,642,851; 6,501,387 and 6,329,925, whichare hereby incorporated herein by reference), a display element backlitby an incandescent light source, or a backlit liquid crystal display(LCD), a video display screen (such as the type described in PCTApplication No. PCT/US03/40611, filed Dec. 19, 2003 and published Jul.15, 2004 as International Publication No. WO 2004/058540, which ishereby incorporated herein by reference) or the like, without affectingthe scope of the present invention.

The heating device may be operable to heat the reflective element at thearea of the display element or may heat the display element itself. Forexample, the rear surface of the reflective element may have atransparent conductive coating or layer, such as an indium tin oxide(ITO), a tin oxide (TO) or the like (such as transparent conductivelayers of the types suitable for use in electrochromic cells and such asdescribed in U.S. Pat. Nos. 6,690,268; 5,668,663; 5,724,187; 5,140,455;5,151,816; 6,178,034; 6,154,306; 6,002,544; 5,567,360; 5,525,264;5,610,756; 5,406,414; 5,253,109; 5,076,673; 5,073,012; 5,117,346;5,910,854; 5,142,407 and 4,712,879, and/or in U.S. patent applicationSer. No. 10/054,633, filed Jan. 22, 2002, now U.S. Pat. No. 7,195,381,and/or in PCT Application No. PCT/US03/29776, filed Sep. 19, 2003 andpublished Apr. 1, 2004 as International Publication No. WO 2004/026633;PCT Application No. PCT/US03/35381, filed Nov. 5, 2003 and published May21, 2004 as International Publication No. WO 2004/042457; and/or in PCTApplication No. PCT/US03/036177, filed Nov. 14, 2003 and published Jun.3, 2004 as International Publication No. WO 2004/047421; and/or U.S.provisional applications, Ser. No. 60/531,838, filed Dec. 23, 2003; Ser.No. 60/553,842, filed Mar. 17, 2004; and Ser. No. 60/563,342, filed Apr.19, 2004, which are hereby incorporated herein by reference), appliedthereto or deposited thereon in at least the area at which the displayelement may be positioned. An electrical current may then be applied tothe transparent conductive layer (such as via a pair of terminalscontacting opposite portions of the transparent conductive layer or thelike) to energize the conductive layer and to heat the conductive layer.For example, the transparent conductive coating or layer may generateheat as electrons or electricity flow from a contact of a power terminalacross the surface or coating or layer to a contact of a groundterminal. The contacts may be spaced apart at generally opposite sidesof the transparent conductive layer and may provide for generallyuniform and thorough heating of the transparent conductive layer whenelectricity is applied to the heating or power terminal.

The display element may be positioned behind the reflective element andtransparent conductive coating and may be next to or urged against oroptically coupled to the transparent conductive coating on the rearsurface of the reflective element. When the electrical current isapplied across the transparent conductive layer, the resistivity in theconductive layer causes the conductive layer to be heated, whichfunctions to heat the display element to enhance the performance of thedisplay element during low temperature conditions. Optionally, othertypes of heating devices may be implemented at or against the displayelement and/or the reflective element, or may be positioned at theprinted circuit board upon which the display element may be mounted,without affecting the scope of the present invention.

Optionally, for example, a heating device may be implemented at or neara display (such as a video display screen displaying, for example,driver information such as navigational information or a view of aninterior or exterior scene, such as a curb side view such as is nowbeing required for certain vehicles in Japan, or a parking/reversingview or the like) to heat the display or display area at least initiallyupon startup of the vehicle in extremely cold conditions. When thevehicle is in a cold climate (such as, for example, in northern Minn. inthe winter time where the temperature may drop to around thirty degreesbelow zero), the heater may be activated on the first ignition cycle ofthe vehicle or when the vehicle is first turned on or the like and whenthe temperature is below a threshold temperature. The heating device mayinclude a thermometer or thermistor or the like to determine the ambienttemperature at the vehicle or at or near the display, and the heater maybe activatable in response to an output of the thermometer. Optionally,if the temperature is below a threshold temperature, the heater may beoperable in a “quick heat mode” to rapidly heat the display so that itworks properly very quickly after startup of the vehicle. The heater maybe operable at a higher than normal power dissipation during the quickheat mode to provide rapid heating or thawing or defrosting of thedisplay when the vehicle ignition is first turned on during winter orcold conditions, but after the initial rapid heating phase is completed,the heater may operate at a lower power dissipation level more suitedfor ongoing heating during the driving event. This is particularlyuseful when the display is associated with a backup aid or reversevision system or the like (such as those described in U.S. Pat. Nos.5,550,677; 5,760,962; 5,670,935; 6,201,642; 6,717,610; 5,877,897 and6,690,268, and/or in U.S. patent applications, Ser. No. 10/010,862,filed Dec. 6, 2001, now U.S. Pat. No. 6,757,109, and Ser. No.10/418,486, filed Apr. 18, 2003, now U.S. Pat. No. 7,005,974, and/or inPCT Application No. PCT/US03/40611, filed Dec. 19, 2003 and publishedJul. 15, 2004 as International Publication No. WO 2004/058540, which arehereby incorporated herein by reference), where it is important for thedisplay to be fully operational at the startup of the vehicle so itprovides a proper or desired display of the rearward field of view ofthe camera as the vehicle is initially backed out of its parking spaceor driveway or the like.

The heating device and the construction of the mirror assembly thus mayprovide heating of a display or display element (such as, for example,heating of a slide out display screen such as the type described in PCTApplication No. PCT/US03/40611, filed Dec. 19, 2003 and published Jul.15, 2004 as International Publication No. WO 2004/058540, which ishereby incorporated herein by reference), such as for a backup aid orrear vision system or the like, during cold temperatures to enhance theperformance of the display during such cold temperatures. The heatingdevice may provide intimate heating of the display medium, such as for aliquid crystal display element or the like, to enhance the performanceof the display element. The heating device may provide such intimateheating of the display medium while not interfering with or heatingother components or circuitry of the mirror assembly. The heating devicemay be included in the construction of the mirror assembly itself, suchas a transparent conductive layer across the display screen or elementor reflective element or such as a wire grid or other heating element orthe like at or near the display area, to intimately heat the displayelement or display medium without substantially heating other componentsand circuitry in the vicinity of the display element. Optionally, theheating device may be activated/deactivated/controlled in conjunctionwith the heating elements for the exterior rearview mirrors of thevehicle (in such applications where the exterior rearview mirrors may beheated or defrosted, such as when a rear window defroster/defogger isactuated or the like). The heating device may utilize or incorporateaspects of heating devices used to heat and defrost exterior rearviewmirror reflective elements, such as the heating means described in U.S.Pat. No. 5,446,576, issued to Lynam et al., which is hereby incorporatedherein by reference, such as a positive thermal coefficient (PTC) heaterelement that is continuously connected to voltage ignition, but thatprincipally only operates at low temperatures, such as less than about10 degrees Celsius or lower. Optionally, a separate temperaturecontroller, such as a thermistor, may be provided at or near the displayin the interior rearview mirror assembly that powers the heater elementat low temperatures.

Optionally, it is envisioned that the cap portion or portions mayinclude a shielding element or sleeve or the like to provide shieldingfrom external fields and unwanted radiation fields. The shielding maycomprise a thin metal or foil member or sleeve or sheet or the like thatis placed over and along an interior surface or portion of the capportion (such that the shielding is within the mirror assembly and thusnot readily visible when the mirror assembly is assembled). Theshielding may be attached to the cap portion or portions so as to beretained thereto during the mirror assembly process. The shieldingmaterial/sheet preferably has a magnetic and/or electromagneticpermeability appropriate for shielding the accessories and the likewithin the cap portion and mirror assembly from external fields andunwanted radiation fields and the like.

Optionally, the cap portion or portions may include a hands free phoneattachment to allow a driver of the vehicle to use a cellular or mobiletelephone via circuitry and microphones and speakers of the mirrorassembly and/or vehicle. The cap portion or portions may include aconnector, such as a plug or socket type of connector or telephonedocking device or the like, for a user to plug their mobile telephoneinto, which would connect the mobile telephone to a communication systemor the like of the mirror assembly or vehicle.

Optionally, and as shown in FIG. 28, the cap portion or portions 16 mayhouse or include a battery 52 for providing power to one or moreelectronic accessories or to a circuit board 58 of the cap portion ormirror assembly (such as, for example, described in U.S. Pat. No.6,690,298, which is hereby incorporated herein by reference). Theaccessory or accessories of the mirror assembly thus may be powered bythe battery such that the mirror assembly or circuitry of the capportion may not have to connect to the power source of the vehicle. Thebattery may be contained within the cap portion and at or near anexterior or outer portion of the cap portion and may be readilyaccessible by a user to facilitate changing of the battery when desiredor necessary. For example, the battery 52 may be within a recess 54 ofcap portion 16 and may be contained therein via a trap door or panel ordoor 56 that may cover battery 52 and recess 54 when closed. Panel 56may be opened and may be removable or may be hingedly attached orotherwise movably attached to cap portion 16 to facilitate access torecess 54 and battery 52. For example, panel 56 may be molded with capportion 16 and may be hingedly attached to cap portion 16 via a livinghinge 56 a along an edge of panel 56. Other means for storing a batteryand selectively accessing the battery may be implemented, withoutaffecting the scope of the present invention. The various accessoriesand electronic content and directly driven or energized displays mayfunction via power from the battery or internal power source of the capportion.

Optionally, and with reference to FIGS. 29-32, an interior rearviewmirror assembly 60 may include a bezel portion 62 of a mirror casing, areflective element 64 and a cap portion or rear portion 66 of the mirrorcasing. The mirror assembly 60 may include a mounting arrangement ormounting assembly 68 for pivotally or adjustably mounting or attachingthe mirror assembly to the vehicle, such as to a windshield of thevehicle or the like. The mounting assembly 68 may include a mounting arm70 having a ball member 70 a at one end and an attachment end ormounting end 70 b opposite to the ball member 70 a. Ball member 70 a maybe pivotally received within a socket 72 that may be positioned at orformed with or established at or attached to an attachment plate 74 atthe reflective element 64. When so positioned, attachment end 70 b mayextend from attachment plate 74 and may insert through an opening 66 ain rear casing portion 66. The attachment end 70 b may then attach ormount to a mounting portion or base portion or mounting base 76, whichin turn may be attached or mounted to the vehicle or to a mountingbutton or the like (not shown) at the windshield or headliner oroverhead console of the vehicle.

In the illustrated embodiment, attachment end 70 b is a threaded stud orend, and is secured to or mounted to the mounting or base portion 76 viainsertion of the threaded end 70 b through an opening 76 a (FIG. 31) inmounting portion 76 and tightening a female fastener or nut 78 ontothreaded end 70 b. The mounting arm 70 thus may have a narrow end forinsertion through the opening 66 a in rear casing portion 66, such thatthe opening in the rear casing portion may be smaller than is typicallyrequired (because typically the ball end of the mounting arm is insertedthrough the opening in the rear casing and snapped into the socket atthe attachment plate). The mounting arm may be inserted into the socketof the attachment plate, which may be attached to the reflective elementat the bezel portion, and then may be inserted through the opening inthe rear casing portion or cap portion as the rear casing portion or capportion is moved toward and into engagement with the bezel portion, suchthat the attachment end of the mounting arm extends or protrudes fromthe rear casing portion or cap portion after the mirror is assembled.The attachment end may then be attached or secured to the mountingportion or base portion via the nut or other type of fastener. As shownin FIG. 29, the mirror assembly may also include a circuit board 80(with circuitry and/or accessories such as those described above), whichmay be attached to the attachment plate 74 or which may be attached tothe cap portion for mirror assemblies of the types described above.

Although shown as having a threaded attachment end for securing themounting arm to a mounting base via a nut or the like, it is envisionedthat the mounting arm may have other forms of attachment ends forfixedly or pivotally or adjustably mounting the mounting arm to amounting base or the like, without affecting the scope of the presentinvention. For example, the attachment end may provide a female fastenerwhich may threadedly receive a male fastener or screw or bolt or stud,or the attachment end may provide a bayonet type fastener, or theattachment end and mounting base may cooperate to provide a snaptogether attachment or the like, or the attachment end and mounting basemay otherwise attach or secure together, such as via adhesive orwelding, such as ultrasonic welding or the like. Optionally, theattachment end may attach to or receive another ball member, which maybe received within a socket at the mounting base, in order to provide adouble ball mounting arrangement. The mounting arm, socket and/ormounting base may comprise plastic or polymeric materials, or may be diecast or otherwise formed, without affecting the scope of the presentinvention.

Optionally, and as shown in FIG. 32, the ball member 70 a of mountingarm 70 may be received in a socket 72′ attached to or positioned at orformed with or established at a toggle assembly 82, such as for aprismatic reflective element. The toggle assembly may be any type oftoggle assembly, such as described above, and may be attached to ormounted to the mirror holder or the mirror casing, whereby theattachment end of the mounting arm may extend or protrude from themirror casing when the toggle assembly and mounting arm are mountedtherein or attached thereto. The attachment end may then connect orattach to the appropriate connector or attachment (such as to themounting base 76 via a fastener or nut 78 as shown in FIG. 32) asdescribed above to adapt the mirror assembly for the particularapplication.

The mounting arrangement of the present invention thus may provide apre-established pivot element or member, such as a ball joint, at theattachment plate of the reflective element or at the toggle assembly orthe like, whereby other attachments or mounting elements may be attachedto the other end of the mounting arm to provide the desired attachmentor mounting arrangement for the particular application of the mirrorassembly. The mounting arm and ball member may be inserted within thesocket and then the backing plate or toggle assembly (at which thesocket may be formed) may be attached or secured to the reflectiveelement with the pre-established pivot joint or element. The ball memberof the mounting arm may already be inserted or snapped into the socketwhen the backing plate or toggle assembly is attached to or juxtaposedwith the reflective element, such that the ball member need not berammed into the socket when the socket is positioned at or juxtaposedwith the reflective element, which avoids the impact or shock to thereflective element that typically occurs when a ball member is rammedinto a socket that is at or attached to or juxtaposed with a reflectiveelement.

The other end of the mounting arm may then be attached, such as via asnap together arrangement or a threaded fastener or the like, to anothermounting portion or base portion or the like at the vehicle. Optionally,the other portion may have a second pivot element or member, such as aball member, already received within a socket at a mounting base, andthe end of the mounting arm may readily attach to the end of the otherball member to mount the mirror assembly in the vehicle. For example,the attachment end of the mounting arm extending from the reflectiveelement assembly may threadedly attach to a corresponding attachment endof another ball member extending from a socket at a base portion at thevehicle. The mounting arrangement thus may provide a single or doubleball mounting arrangement without the need to press or ram the ballmember or ball members into the respective socket after the socket isattached to or positioned at the reflective element. The mountingarrangement also avoids the impact or shock of ramming the opposite ballmember into the respective socket at the mounting base or button.

Because the pivot element or member, such as a ball member or ballmembers, is/are already inserted into their respective sockets so thatthe pivot joints are pre-established at the reflective element andmounting base, the ball member(s) do not have to be rammed or snappedinto place in their respective sockets during installation of the mirrorassembly, which substantially reduces the stresses at the reflectiveelement to substantially limit or reduce cracking of the reflectiveelement during installation of the mirror assembly. The mountingarrangement thus may substantially reduce the stresses at the reflectiveelement during the installation processes.

Also, because the mounting arm may have an attachment end opposite aball member, the ball member may be received or pre-established in anysuitable or corresponding socket of a substantially universal bezelportion or reflective element assembly portion, whereby the attachmentend of the mounting arm may be attached to any corresponding connectoror attachment at the vehicle to complete the installation process forthe respective mirror assembly. The present invention thus may provide asubstantially universal and pre-established ball joint or pivot joint atthe reflective element (and thus lends itself to provision of auniversal reflective element assembly portion) that does not requireattachment or insertion of the ball member at a later time (after thesocket portion is positioned at or established at or juxtaposed with thereflective element), and may provide the capability of adapting orconfiguring the mounting arm to fixedly or pivotally or adjustablyattach to a particular mounting base or vehicle portion or console orthe like for the particular mirror application. The mounting arrangementmay be suitable for applications with the cap portion and mirror holderassemblies as described above, or may be suitable for applications withother types of mirror assemblies, such as a mirror assembly of the typeshown in FIG. 29, without affecting the scope of the present invention.

Optionally, and as shown in FIG. 31, the mounting arm 70 may comprise ahollow mounting arm that provides a wiring channel or passageway 70 ctherethrough. One or more wires or cables or the like thus may be routedthrough the mounting arm to provide power and/or control to thecircuitry and accessories within the mirror assembly. As can be seen inFIGS. 30 and 31, the wires may route along and within the mounting base76 and through the mounting arm and into the mirror casing or housing.Optionally, the attachment end of the mounting arm may include aconnector and may plug into or connect to a corresponding connector atthe mounting base or the like to establish mechanical and electricalconnections (such as via utilizing aspects described in U.S. Pat. Nos.6,672,744; 6,669,267; 6,402,331; 6,386,742 and 6,124,886, and/or U.S.patent applications, Ser. No. 10/739,766, filed Dec. 18, 2003, now U.S.Pat. No. 6,877,888, and Ser. No. 10/355,454, filed Jan. 31, 2003, nowU.S. Pat. No. 6,824,281, which are hereby incorporated herein byreference) as the mirror assembly is mounted within the vehicle. Themounting arm may include wiring therethrough to electrically connect theconnector or attachment end to the circuitry within the mirror assembly.

As shown in FIGS. 29 and 30, the mounting base 76 may have a hollow bodyportion 76 b that may extend along the interior surface of thewindshield and that may extend generally downwardly from an attachingportion 76 c of mounting base 76. The attaching portion 76 c may attachto the mounting button or other attachment element (not shown)positioned at or attached to the interior surface of the windshield orthe headliner or an overhead console of the vehicle to position themounting base at the desired or appropriate location at the vehicle. Asshown in FIG. 29, the mounting base 76 may include a cover plate 76 dthat may encase or enclose the body portion 76 b to provide a finishedappearance to the mounting base 76 along the windshield. Optionally, thebody portion 76 b may include or receive one or more electronic elementsor accessories, such as a rain sensor or the like (such as a rain sensorof the types described in commonly assigned U.S. Pat. Nos. 6,516,664;6,320,176; 6,353,392; 6,313,454; 6,341,523 and 6,250,148; and/or in U.S.patent applications, Ser. No. 10/355,454, filed Jan. 31, 2003, now U.S.Pat. No. 6,824,281; and Ser. No. 10/348,514, filed Jan. 21, 2003, nowU.S. Pat. No. 6,968,736, which are all hereby incorporated herein byreference), that may be positioned at the windshield and that may beoptically coupled to the windshield, depending on the particularapplication. In such embodiments, the cover plate 76 d may include oneor more openings or apertures at which the rain sensor camera or sensingdevice may be positioned.

Although the mirror assembly may include a prismatic reflective element,it is envisioned that the cap portion or portions may include controlsor circuitry for controlling electro-optic or electrochromic reflectiveelements, such as electrochromic reflective elements of one or moreexterior rearview mirror assemblies of the vehicle. The circuitry orcontrols may control the dimming of the exterior mirrors, such as in aknown manner, such as described in commonly assigned U.S. Pat. Nos.5,140,455; 5,151,816; 6,178,034; 6,154,306; 6,002,544; 5,567,360;5,525,264; 5,610,756; 5,406,414; 5,253,109; 5,076,673; 5,073,012;5,117,346; 5,724,187; 5,668,663; 5,910,854; 5,142,407 and/or 4,712,879,which are hereby incorporated herein by reference. Optionally, the capportion or portions may include one or more photo-sensors, such as anambient light photo-sensor and a glare sensor, and the controls orcircuitry may control the exterior electro-optic or electrochromicreflective elements in response to such photo-sensors.

Optionally, the exterior rearview mirror assemblies of the vehicle maycomprise electrochromic mirror reflective element assemblies, while thesensors and electronic circuitry for glare detection and ambient lightdetection may be positioned inside the vehicle, such as at an interiorelectrochromic rearview mirror assembly. In applications where theexterior mirror assemblies comprise passenger and/or driver sideelectrochromic exterior rearview mirror assemblies, such as may beimplemented in large vehicles, such as SUVs and the like, theelectrochromic controls and circuitry may be contained within theexterior rearview mirror assemblies or the exterior electrochromicreflective element assemblies may be slaved off of the controls andcircuitry of an associated electrochromic interior rearview mirrorassembly of the vehicle. Optionally, it is envisioned that such sensorsand electronic circuitry may be positioned at or near or incorporatedinto an interior prismatic rearview mirror assembly having a prismaticreflective element. The circuitry and the glare sensor and/or ambientlight sensor (such as a photo sensor or the like, such as a glare sensorand/or an ambient light sensor and electrochromic automatic dimmingcircuitry of the types described in U.S. Pat. Nos. 4,793,690 and5,193,029, and U.S. patent application Ser. No. 10/456,599, filed Jun.6, 2003, now U.S. Pat. No. 7,004,593, which are all hereby incorporatedherein by reference) thus may be positioned at or in or near orincorporated into the added feature prismatic interior rearview mirrorassembly. The sensors may be positioned at or within the prismaticinterior rearview mirror assembly such that the glare sensor is directedgenerally rearwardly (in the direction opposite to the forward directionof travel of the vehicle), such as through a bezel portion of theprismatic interior rearview mirror assembly, while the ambient sensormay be directed generally forwardly (in the direction of travel of thevehicle) or downwardly toward the floor of the vehicle when the mirrorassembly is installed in the vehicle.

It is further envisioned that the sensors and/or control circuitry maybe provided at, on or within a cap portion of the interior rearviewmirror assembly and, thus, may be provided as an option for vehiclesthat offer the electrochromic exterior rearview mirror assemblies with abase or prismatic interior rearview mirror assembly. The appropriate capportion (with electrochromic control circuitry and sensors and the likeincorporated therein) may be selected and attached to the interiorrearview mirror reflective element assembly portion to provide glare andlight sensing capability and electrochromic reflective element assemblycontrol capability to the interior rearview mirror assembly. Optionally,the cap portion may include the glare sensor in a location therein thatmay extend downward or outward from the cap portion so that the glaresensor may be directed generally rearward toward the rear of the vehiclewhen the mirror assembly is installed in the vehicle. For example, thecap portion may include a gondola or pod extending therefrom for housingthe sensor or sensors and/or control circuitry. Alternately, the capportion may include the glare sensor at a location therein that mayalign with a view port or the like through the reflective element, suchas for applications where, for example, the mirror assembly includes acompass/display system or other display system, such as the typesdescribed herein and/or the types disclosed in U.S. patent applicationSer. No. 10/456,599, filed Jun. 6, 2003, now U.S. Pat. No. 7,004,593,which is hereby incorporated herein by reference. In such applications,the ambient sensor may provide a dual function of providing an input tothe control circuitry for controlling the exterior electrochromicreflective element assemblies and providing an input to the controlcircuitry for the display element of the interior rearview mirrorassembly. The cap portion may include the ambient light sensor in alocation and orientation whereby the ambient light sensor is directedgenerally forwardly in the direction of travel of the vehicle when themirror assembly is installed in the vehicle.

Optionally, the electrochromic controls and glare/ambient light sensorsthus may be provided in a cap portion (such as in a protrusiontherefrom, such as a gondola or the like) and, thus, may be provided asan option for use with a common bezel and prismatic reflective elementassembly. The present invention thus provides for optional controls andcircuitry and sensors for optional accessories, such as electrochromicexterior rearview mirror assemblies, while providing a common bezel andprismatic reflective element and mounting attachment. The desired orappropriate cap portion (with the desired or appropriatecontrols/sensors/circuitry) may be selected for a particular applicationand may be snapped onto or otherwise attached to the common bezel andprismatic reflective element assembly. The assembled mirror assembly maythen be installed in the appropriate vehicle with the exteriorelectrochromic mirror assemblies. The present invention thus may provideadded feature prismatic interior rearview mirror assemblies, where thedesired content of the mirror assemblies may be selected and provided ona respective optional cap portion while the rest of the mirrorassemblies comprise common components.

Although shown and described as having a prismatic reflective element,the interior rearview mirror assembly of the present invention mayoptionally have an electro-optic or electrochromic mirror assembly. Theelectrochromic mirror element of the electrochromic mirror assembly mayutilize the principles disclosed in commonly assigned U.S. Pat. Nos.6,690,298; 5,140,455; 5,151,816; 6,178,034; 6,154,306; 6,002,544;5,567,360; 5,525,264; 5,610,756; 5,406,414; 5,253,109; 5,076,673;5,073,012; 5,117,346; 5,724,187; 5,668,663; 5,910,854; 5,142,407 and/or4,712,879, which are hereby incorporated herein by reference, and/or asdisclosed in the following publications: N. R. Lynam, “ElectrochromicAutomotive Day/Night Mirrors”, SAE Technical Paper Series 870636 (1987);N. R. Lynam, “Smart Windows for Automobiles”, SAE Technical Paper Series900419 (1990); N. R. Lynam and A. Agrawal, “Automotive Applications ofChromogenic Materials”, Large Area Chromogenics: Materials and Devicesfor Transmittance Control, C. M. Lampert and C. G. Granquist, EDS.,Optical Engineering Press, Wash. (1990), which are hereby incorporatedby reference herein; and/or as described in U.S. patent application Ser.No. 10/054,633, filed Jan. 22, 2002, now U.S. Pat. No. 7,195,381, whichis hereby incorporated herein by reference. Optionally, theelectrochromic circuitry and/or a glare sensor and circuitry and/or anambient light sensor and circuitry may be provided on one or morecircuit boards at the cap portion or portions of the mirror assembly.

Optionally, the electrochromic reflective element may include one ormore displays, such as for the accessories or circuitry described above.The displays may be similar to those described above, or may be of typesdisclosed in U.S. Pat. Nos. 5,530,240 and/or 6,329,925, which are herebyincorporated herein by reference, and/or may be display-on-demand ortransflective type displays, such as the types disclosed in U.S. Pat.Nos. 6,690,298; 5,668,663 and/or 5,724,187, and/or in U.S. patentapplication Ser. No. 10/054,633, filed Jan. 22, 2002, now U.S. Pat. No.7,195,381; and/or in U.S. provisional application Ser. No. 60/525,952,filed Nov. 26, 2003, and/or in PCT Application No. PCT/US03/29776, filedSep. 19, 2003 and published Apr. 1, 2004 as International PublicationNo. WO 2004/026633, which are all hereby incorporated herein byreference.

Optionally, and with reference to FIG. 33A, a reflective elementassembly portion 84 may hold or receive or comprise an electrochromicreflective element assembly or cell 86, which includes a front substrate88 and a rear substrate 90 and an electrochromic medium 92 sandwichedtherebetween. In the illustrated embodiment, the reflective elementassembly or cell 86 comprises a front substrate 88 that is larger thanthe rear substrate 90 so as to create a relief region or overhang regionor ledge 93 around the perimeter of the reflective element assembly,such as described in PCT Application No. PCT/US03/35381, filed Nov. 5,2003 and published May 21, 2004 as International Publication No. WO2004/042457; and/or in U.S. provisional applications, Ser. No.60/553,842, filed Mar. 17, 2004; and Ser. No. 60/563,342, filed Apr. 19,2004, which are hereby incorporated herein by reference.

The larger front substrate 88 allows the bezel portion or molding 94 tobe molded around the electrochromic reflective element assembly andallows the bezel portion to shrink and directly stress the frontsubstrate 88 without placing the interpane seal 96 under the hoopstresses and shear stresses that typically occur with conventionalelectrochromic cells or reflective element assemblies (where the frontand rear substrates are offset one to another such that any bezelshrinkage typically places the front substrate in shear stress relativeto the rear substrate, potentially leading to failure of the sealtherebetween that protects the electrochromic medium from the outsideenvironment) when the bezel portion cools and contracts around the cell.The bezel portion or molding 94 thus may be formed around the reflectiveelement assembly or cell, and the cap portion (not shown in FIG. 33A)may be provided at a later step after the bezel portion has cooledaround the reflective element assembly (such as described above) toprovide a modular electrochromic mirror assembly in accordance with thepresent invention. Optionally, the bezel portion may be formed of a softpolymer or impact absorbing material (such as a soft touch material asdescribed above, and/or preferably having a Shore A durometer value ofless than about 110 Shore A, more preferably less than about 90 Shore A,and most preferably less than about 70 Shore A) at or around theperimeter of the front substrate 88 or of the front or first surface 88b of the front substrate 88, or a soft or impact absorbing trim portionor element may be provided at or around the perimeter of the frontsubstrate 88, without affecting the scope of the present invention.

The front substrate 88 includes a transparent conductive coating orlayer 89 (such as an indium tin oxide (ITO), a tin oxide (TO) or thelike) on its rear surface 88 a (the second surface of the cell), whilethe rear substrate 90 includes a metallic conductive coating or layer orlayers or stack of coatings or layers 91 on its front surface 90 a (thethird surface of the cell), such as is generally done withelectrochromic reflective element assemblies, and such as by utilizingaspects described in U.S. Pat. Nos. 6,690,268; 5,668,663; 5,724,187;5,140,455; 5,151,816; 6,178,034; 6,154,306; 6,002,544; 5,567,360;5,525,264; 5,610,756; 5,406,414; 5,253,109; 5,076,673; 5,073,012;5,117,346; 5,910,854; 5,142,407 and 4,712,879, and/or in U.S. patentapplication Ser. No. 10/054,633, filed Jan. 22, 2002, now U.S. Pat. No.7,195,381, and/or in PCT Application No. PCT/US03/29776, filed Sep. 19,2003 and published Apr. 1, 2004 as International Publication No. WO2004/026633; PCT Application No. PCT/US03/35381, filed Nov. 5, 2003 andpublished May 21, 2004 as International Publication No. WO 2004/042457;and/or in PCT Application No. PCT/US03/036177, filed Nov. 14, 2003 andpublished Jun. 3, 2004 as International Publication No. WO 2004/047421;and/or U.S. provisional applications, Ser. No. 60/531,838, filed Dec.23, 2003; Ser. No. 60/553,842, filed Mar. 17, 2004; and Ser. No.60/563,342, filed Apr. 19, 2004, which are hereby incorporated herein byreference.

As shown in FIG. 33A, the metallic conductive coating or layer or layers91 may be removed from (or not disposed at) a perimeter region 90 b ofthe front surface 90 a of rear substrate 90, and the interpane seal 96may be disposed around the masked or uncoated perimeter region, in orderto electrically isolate the conductive coatings 91 from the perimeteredge of the rear substrate 90, such as described in U.S. provisionalapplications, Ser. No. 60/553,842, filed Mar. 17, 2004; and Ser. No.60/563,342, filed Apr. 19, 2004, which are hereby incorporated herein byreference. The conductive coatings or layers 91 may provide a tab outregion (not shown in FIG. 33A) along the front surface of the rearsubstrate to provide for electrical connection between the third surfacecoating 91 and the perimeter edge of the substrate (such as described inU.S. provisional applications, Ser. No. 60/553,842, filed Mar. 17, 2004;and Ser. No. 60/563,342, filed Apr. 19, 2004, which are herebyincorporated herein by reference. A conductor or electrical connector100 may connect to the conductive coating 89 via a solder or conductivestrip 101 around the overhang region, while a second conductor orelectrical connector (not shown in FIG. 33A) may connect to theconductive coating 91 via connection to the tab out region. Thereflective element assembly may include a reflective perimeter regionaround the perimeter of the reflective element assembly or may have anopaque or blackened or darkened perimeter region, such as by utilizingthe principles described in U.S. Pat. No. 5,066,112, which is herebyincorporated herein by reference, in order to at least partially concealthe seal 96 from being readily viewable by the driver of the vehicle.

Optionally, and with reference to FIG. 33B, a reflective elementassembly portion 84′ may hold an electro-optic reflective elementassembly 86, such as an electrochromic reflective element assembly orcell, and may include a mounting or attachment plate 98 positioned atthe rear surface of the reflective element assembly 86 (the fourthsurface of the cell). The bezel portion or molding 94′ may be molded orformed around the reflective element assembly 86 and around or at theattachment plate 98 to retain the attachment plate 98 and the reflectiveelement assembly 86 within the bezel portion or molding 94′. As can beseen in FIG. 33B, the mounting plate 98 may include protrusions orrecesses or the like 98 a at least partially around its perimeter edgeto facilitate mechanical connection and securement of the bezel portion94′ (such as by snap on or snap in) to the mounting plate 98 when thebezel portion 94′ is molded around the mounting plate 98. The attachmentplate 98 may include a pivot joint or element 102 established or formedthereon. The reflective element assembly portion 84′ may be otherwisesubstantially similar to reflective element assembly portion 84,discussed above, such that a detailed description of the reflectiveelement assembly will not be repeated herein. The components that arecommon with the reflective element assemblies 84 and 84′ are shown withthe same reference numbers in FIGS. 33A and 33B.

Therefore, the reflective element assembly portion may be formed ormolded with the molding or bezel portion molded or formed around thelarger front substrate to contain the reflective element assembly orcell within or at the bezel portion. The pivot element or joint 102 maybe formed or established at the rear of the reflective element assembly,such as in the manners described above, and the mounting arm 104 mayextend generally rearwardly from the pivot joint. The cap portion (suchas cap portion 166 shown in FIG. 33C) may then receive the mounting arm102 through an opening or the like in the cap portion such that themounting arm extends from the cap portion after the cap portion isattached to or snapped to the reflective element assembly portion (suchas at structure 95 shown in FIG. 33C). The electrical connectors of thereflective element assembly portion may connect to the appropriateelectrical connectors or terminals or circuitry of the cap portion asthe cap portion is assembled to or attached to the reflective elementassembly portion, such as in the manners described above, in order toprovide electrical power and/or control to the electrochromic cell.

The electrochromic reflective element assembly portion of the presentinvention thus may comprise a standard or universal or common reflectiveelement assembly or cell and mirror holder or bezel portion, which maythen be attached to a customized or selected or desired cap portion, asdescribed above. Optionally, the reflective element assembly portion maybe customized as well. For example, a selected bezel material may bemolded around a common reflective element assembly or cell. Thereflective element assembly portion may be formed by placing anelectrochromic cell into a mold cavity (such as face down into the moldcavity with the rear surface of the rear substrate facing upward), andthe plastic piece or mounting plate (preferably with a pivot element ormember already established therein or thereon) may be inserted into themold or placed generally at or on the rear surface of the rear substrateof the reflective element assembly or cell (i.e. the fourth surface ofthe cell). The mounting plate may be generally smaller than the profileof the rear substrate and may include the pivot element or socket formedthereon (or such pivot components may be added or attached or moldedlater). Optionally, the mounting plate may include electronic circuitryand the like, such as for making the electrical connection to theelectrical connectors of the cell and/or for providing other electroniccontent or features or functions as may be desired (such as displayelements for displaying information through the cell to a driver of thevehicle or the like, or such as ports or aperture for aligning withdisplay elements of the cap portion so that information may be displayedor projected through the apertures in the mounting plate and through thecell to a driver of the vehicle). The bezel portion or molding may thenbe molded (such as via injection molding or reaction injection moldingof a desired or selected or appropriate material into the mold cavity)to form the bezel portion around the perimeter of the front substrate(such as described above).

Optionally, the electrochromic reflective element assembly portion maybe readily customized by injection molding a selected material into themold to form the bezel portion of a selected or customized material. Forexample, the material may be selected to be a desired color, or may beselected to have desired properties, such as, for example, a soft touchor desired feel or appearance or finish or the like. The presentinvention thus may provide a common cell and attachment or mountingplate (and pivot element or joint), but may readily customize theappearance and/or feel of the bezel portion or molding to provide aparticular, selected and customized reflective element assembly portion,while utilizing the same molding tool or mold to form the customizedmolding or bezel portion. Optionally, the reflective element assembly orcell and attachment or backing plate may comprise standard or commoncomponents for multiple mirror assemblies, and may be placed in desiredor appropriate molds for molding the appropriate bezel portion for aparticular mirror application. The customized reflective elementassembly portion may then be attached to the desired or selected orcustomized cap portion as described above, and the electricalconnections of the electronic circuitry and the like at the plate of thereflective element assembly portion may be made to the corresponding orappropriate connectors or circuitry of the cap portion as the capportion is attached to the reflective element assembly portion. Althoughshown and described as molding a bezel portion around the perimeterregion of a larger front substrate (which is larger than the rearsubstrate) of an electrochromic reflective element assembly or cell, itis envisioned that the bezel portion or molding may be molded or formedaround other types of electrochromic reflective element assemblies orcells (such as flush cells or offset or staggered cells or the like),and/or may be molded or formed around prismatic reflective elements andthe like (such as the bezel portion or molding 94″ at the prismaticreflective element 86′ shown in FIG. 33C), without affecting the scopeof the present invention.

Optionally, and such as described in PCT Publication No. WO 03/095269,published Nov. 20, 2003, which is hereby incorporated by referenceherein, an electro-optic rearview mirror assembly portion may comprisean electro-optic reflective element assembly or unit or cell, such as anelectrochromic reflective unit or cell (whose reflectivity is variablein response to an electrical voltage applied thereto), and an electricalcircuit for controlling operation of the mirror cell in response to oneor more one light sensors. The interior mirror assembly portion may alsocomprise at least one pivot element or member, such as a ball and socketmember, which allows angular adjustment of the mirror reflective elementwhen the mirror assembly is mounted in the vehicle. Optionally, the ballmember may include a plurality of electrical contacts on an exposedsurface thereof for sliding engagement by respective counter-contactsover a range of angular movement of the mirror unit for supplying powerto the electrical circuit from a vehicle electrical system external tothe mirror assembly. Optionally, other means for providing electricalpower and/or control to the circuitry/accessories of the mirror assemblymay be provided (such as a wire or cable along an exterior surface orportion of the mounting arm or member or the like), without affectingthe scope of the present invention.

Optionally, a prismatic mirror assembly portion and cap portion of thepresent invention may include electrochromic drive circuitry forcontrolling the exterior electrochromic reflective elements of theexterior rearview mirror assemblies of the vehicle, such as describedabove. The cap portion may include a glare sensor and an ambient sensorto determine the glare levels and ambient light levels and the controlcircuitry may adjust the dimming of the exterior mirrors accordingly.The glare sensor may receive the light through an aligned port in thereflective element or may receive light via a light pipe or the like,without affecting the scope of the present invention. The cap portionthus may provide electrochromic control circuitry for applications wherethe vehicle may have exterior electrochromic mirror assemblies, whilethe interior rearview mirror assembly may comprise a base or prismaticmirror that may otherwise not include such control circuitry. The capportion of the present invention thus may provide a low cost conversionof an interior rearview mirror to provide electrochromic mirror controlfor the exterior rearview mirrors of the vehicle.

Optionally, and with reference to FIGS. 34 and 35A-D, an interiorrearview mirror assembly 110 may be attachable or mountable to awindshield accessory module 112, which may be attachable or mountable toan interior surface of the windshield of a vehicle, such as at amounting button or the like. Windshield accessory module 112 may includea body portion 114 that extends generally along the windshield and mayinclude a head portion 116 at the upper end of the body portion 114generally above the mirror assembly 110 and viewable by a driver of thevehicle when the windshield accessory module 112 and mirror assembly 110are mounted in a vehicle, such as in a similar manner as described inU.S. patent application Ser. No. 10/355,454, filed Jan. 31, 2003, nowU.S. Pat. No. 6,824,281, which is hereby incorporated herein byreference. Windshield accessory module 112 may include one or moreaccessories or circuitry therein, and may include one or more userinterface controls or inputs and/or a display or indicator or indicatorsor the like at the head portion that are readily viewable and/oraccessible above the mirror assembly, such as discussed below and asshown in FIGS. 35A-D and/or as described in U.S. patent application Ser.No. 10/355,454, filed Jan. 31, 2003, now U.S. Pat. No. 6,824,281, whichis hereby incorporated herein by reference. As shown in FIGS. 34 and35A, a wiring or cabling conduit 118 may extend upward from the bodyportion 114 and along the windshield 111 to conceal and route the wiringharness between the headliner of the vehicle and the windshieldaccessory module 112.

Preferably, the windshield accessory module may be configured to attachto a typical mounting button or the like for an interior rearview mirrorassembly, and may include a replica of the mounting button or the likefor the mirror assembly to mount thereto. The accessory module thus mayattach to the existing button on the windshield and the mirror assemblymay be attached to the button on the accessory module in the samemanner. The mirror assembly may comprise a modular mirror assembly asdescribed above, or may comprise other types of prismatic orelectro-optic or electrochromic mirror assembly, without affecting thescope of the present invention. As shown in FIG. 34, a wiring harness119 and connector or plug 119 a may extend from accessory module 112 andplug into the back of the mirror casing or cap portion, such as in asimilar manner as described above. The accessory module thus may providean aftermarket addition to add additional electronic content oraccessories, without having to replace the mirror assembly. Theaccessory module of the present invention thus may provide the desiredaccessories or options, while providing the vehicle manufacturer and/orthe customer the freedom to select any mirror assembly. Optionally, foraftermarket applications, the windshield accessory module may bebattery-operated and may include a battery compartment for receiving andconnecting to a battery or power source or the like.

As shown in FIG. 35A, windshield accessory module 112 may include or maybe associated with a garage door opening system, and head portion 116may include one or more user actuatable inputs 120 a-c for controllingor actuating the garage door opening system. Head portion 116 may alsoinclude an icon or indicia 122 or the like, which may be illuminated orback lit via a light source in head portion 116 to indicate to the userof the garage door opening system that the system is activated or thatthe button or input was successfully actuated. The garage door openingsystem may comprise a trainable garage door opening system and/or mayutilize principles disclosed in U.S. Pat. Nos. 6,396,408; 6,362,771;5,798,688 and 5,479,155; and/or U.S. patent application Ser. No.10/770,736, filed Feb. 3, 2004, now U.S. Pat. No. 7,023,322, which arehereby incorporated herein by reference.

Optionally, and with reference to FIG. 35B, the windshield accessorymodule 112′ may also or otherwise include or be associated with atelematics system or cellular telephone system or the like. The headportion 116′ thus may provide user inputs 124 a, 124 b, 124 c foractuating the system, placing a telephone call and ending a telephonecall, respectively. The head portion 116′ may also include a microphone126 for receiving voice or audio signals from within the cabin of thevehicle, such as via a microphone system of the types described in U.S.Pat. Nos. 6,243,003; 6,278,377 and/or 6,420,975, and/or in PCTApplication No. PCT/US03/308877, filed Oct. 1, 2003 and published Apr.15, 2004 as International Publication No. WO 2004/032568, which arehereby incorporated herein by reference. In the illustrated embodimentof FIG. 35B, the head portion 116′ includes user inputs and/orindicators 120 a′, 120 b′, 120 c′ for controlling and actuating thegarage door opening system and/or for indicating successful operation ofthe garage door opening system, such as described above.

Optionally, and with reference to FIG. 35C, the windshield accessorymodule 112″ may also or otherwise include or be associated with a tirepressure monitoring system. The head portion 116″ may include a display128 that includes a pressure display 128 a for displaying the tirepressure of a particular tire of the vehicle and indicators or lightsources 128 b for indicating which tire the display 128 a is showing thepressure for. Head portion 116″ may also include a reset button or input128 c for resetting the tire pressure monitoring system. The tirepressure monitoring system may comprise any tire pressure monitoringsystem, and may utilize the principles described in U.S. Pat. Nos.6,124,647; 6,294,989; 6,445,287; 6,472,979 and/or 6,731,205, which arehereby incorporated herein by reference. The head portion 116″ may alsoinclude one or more user inputs and/or indicators 120 a″, 120 b″, 120 c″for controlling and actuating the garage door opening system and/or forindicating successful operation of the garage door opening system, suchas described above.

Optionally, and with reference to FIG. 35D, the windshield accessorymodule 112′″ may also or otherwise include or be associated with anavigational system for providing instructions to the driver to followto arrive at a desired or input destination. The head portion 116″ mayinclude a display screen or display device 130 for providing directionalheading or driving instructions to the driver. For example, the displaydevice 130 may display the next step to follow and may indicate how farthe vehicle has to travel until it arrives at the next turn orintersection. The head portion 116′″ may also include one or more userinputs or buttons 132 for controlling the navigational display and/orfor scrolling through the instructions being displayed by the displaydevice 130. The navigational system may be associated with or controlledor adjusted by a global positioning system of the vehicle and/or atelematics system of the vehicle and/or a compass system of the vehicle,and may utilize principles such as used in the compass and/ornavigational systems of the types described in U.S. Pat. Nos. 6,678,614;6,477,464; 5,924,212; 4,862,594; 4,937,945; 5,131,154; 5,255,442 and/or5,632,092, and/or U.S. patent applications, Ser. No. 10/456,599, filedJun. 6, 2003, now U.S. Pat. No. 7,004,593; Ser. No. 10/645,762, filedAug. 20, 2003, now U.S. Pat. No. 7,167,796; and Ser. No. 10/422,378,filed Apr. 24, 2003, now U.S. Pat. No. 6,946,978; and/or PCT ApplicationNo. PCT/US03/40611, filed Dec. 19, 2003 and published Jul. 15, 2004 asInternational Publication No. WO 2004/058540, which are all herebyincorporated herein by reference. As shown in FIG. 35D, head portion116″ may also include one or more user inputs and/or indicators 120 forcontrolling and actuating the garage door opening system and/or forindicating successful operation of the garage door opening system, suchas described above.

The desired accessory module or content may be used with any mirrorassembly and, for aftermarket applications, may be used with an existingmirror assembly in the vehicle. The existing mirror assembly may beremoved from the mounting button and the windshield module may beattached to the windshield button and the mirror assembly may beattached to the button of the module. Optionally, and particularly foraftermarket applications, the accessory module may include a powersource or battery for providing power to the electronic accessoriescontained within the module and/or within an associated mirror assembly.

Although certain examples of the controls and/or displays that may beprovided at the head portion of the windshield accessory module areshown in FIGS. 35A-D and described above, clearly other displays and/oruser inputs and/or accessories or functions or features may be providedwithin or at the windshield accessory module, without affecting thescope of the present invention. The desired features or content may beprovided on a circuit board and may include display elements and/ordisplay screens or panels or the like. The circuit board and associateddisplay elements and circuitry and inputs (or appropriate or selected ordesired display elements and the like) may be mounted to or attached toor snapped into a common or universal body or base portion to convert orform the desired windshield electronics module for the particularapplication. If the screen or circuitry is larger than the standard headsize of the module, a larger cap portion (such as shown in FIGS. 35B and35D) may be implemented to contain and conceal the circuitry and thelike within the head portion. The windshield electronics module oraccessory module of the present invention thus provides various moduleswith the desired features or content, while utilizing common oruniversal components.

The windshield electronics module of the present invention thus easesassembly of various modules having varied content, and eases disassemblyand repair of the modules. Optionally, however, the module may be sealedto contain the circuit board and display elements therewithin, withoutaffecting the scope of the present invention. The components of themodule, such as the telematics controls and the like, may be associatedwith other components and/or circuitry and/or systems of vehicle, suchas a vehicle electronic or communication system, and may be connectedvia a hard wire or via various protocols or nodes, such as Bluetooth,SCP, UBP, J1850, CAN J2284, Fire Wire 1394, MOST, LIN and/or the like,depending on the particular application.

Therefore, the present invention provides a modular prismatic interiorrearview mirror assembly which may have features, such as electronicaccessories and/or displays or the like. The accessories or circuitrymay be attached to one or more cap portions which may snap or otherwiseaffix or secure or mount to the rear portion of the mirror holder orbezel portion or reflective element assembly portion. The mirror holdermay receive the reflective element, which may be a prismatic reflectiveelement or an electro-optic or electrochromic reflective element, soonafter the mirror holder is formed or heated, such that the reflectiveelement may be installed to the mirror holder without a separate bezelportion. The cap portions and associated accessories and/or circuitrymay be mounted to the mirror holder after the reflective element isinstalled and after the mirror holder has cooled and shrunk. The capportion of the present invention thus avoids the increased costsassociated with a two piece mirror holder having a separate bezelportion which is secured to the mirror holder to secure the reflectiveelement at the mirror holder. The cap portions may be selected to haveaccessories and/or circuitry corresponding to openings in the mirrorholder and/or to displays or display icons or the like at the reflectiveelement. The cap portion may be selected to be formed of a differentmaterial than the bezel portion or molding, so as to provide the desiredmaterial properties and characteristics to both the bezel portion andthe cap portion.

As described in PCT Application No. PCT/US03/35381, incorporated above,and as can also be seen with reference to FIG. 36, an electro-optic orelectrochromic cell or reflective element assembly 210, such as for aninterior or exterior rearview mirror assembly of a vehicle, includes afront substrate 212 and a rear substrate 214, with an electro-optic orelectrochromic medium 216 disposed or sandwiched therebetween. Frontsubstrate 212 includes an opaquifying or darkening or hiding conductivecoating or layer 219 (such as, for example, an opaque or blackconductive epoxy or dark colored conductive frit or chromeoxide/metallic chrome bilayer or the like, or other materials) appliedor deposited around the border or perimeter of the front substrate 212.The opaquifying layer 219 may at least partially wrap around theperimeter edges of the substrate so that an edge portion 219 c ofopaquifying layer 219 extends at least partially along the perimeteredge 212 c of substrate 212. The front substrate 212 also includes asemi-conductive, transparent coating or layer 218 (such as an ITO layeror doped ITO layer or the like) applied to or deposited on the rearsurface 212 a of front substrate 212 and overlapping the opaquifying orhiding conductive border layer or coating 219. Alternately, thesemi-conductive layer 518 may be applied to or deposited on the rearsurface of front substrate first, and then the opaquifying or blackconductive layer may be applied to or deposited on the perimeter regionof the semi-conductive layer.

The rear substrate 214 includes a metallic or conductive layer orcoating 220 applied to or deposited on and substantially over the thirdsurface 214 a of rear substrate 214. The outer perimeter edge area orborder region of the third surface 214 a of the rear substrate 214 maybe masked while the metallic reflector 220 is applied, such that theborder region of the front surface 214 a of substrate 214 provides anon-conductive surface or path or raceway 214 e (such as a glass surfaceor the like) at least partially around the metallic reflector 220 andproximate to the edge of substrate 214.

As shown in FIG. 36, the front substrate has a height dimension that isgreater than a corresponding height dimension of the rear substrate,such that the upper perimeter region or edge portion 212 f and lowerperimeter region or edge portion 212 g of front substrate 212 extendbeyond the corresponding perimeter regions or edge portions 214 f, 214 gof rear substrate 214 and define upper and lower overhang regions 212 h,212 i. The connector or connectors may connect to the conductive layerat the rear surface of the front substrate at the overhang region orregions 212 h, 212 i and thus may not interfere or overlap the perimeteredge of the front substrate. The overhang regions of the front substraterelative to the rear substrate thus may allow for the electricalconnectors to connect to the respective conductive layers substantiallyor entirely within the viewable profile of the front substrate byextending along the respective perimeter edges of the rear substrate,such that the connectors do not overlap the perimeter regions of thefront substrate and, thus, are not viewable at the front surface of thefront substrate. The front substrate may include a hiding layer orconcealing layer at the perimeter regions or overhang regions, such asat the rear surface of the front substrate, to substantially hide orconceal the connectors and the seal of the reflective element assembly.The reflective element assembly thus may be suitable for a bezelless orminimal bezel mirror assembly.

As also described in PCT Application No. PCT/US03/35381, incorporatedabove, and as can also be seen with reference to FIG. 36, reflectiveelement assembly 210 may provide an electrically conductive opaque orhiding or concealing layer 219 at least substantially around theperimeter edges of the front substrate, with the transparentsemi-conductive layer 218 overlapping the opaque conducting layer 219 inthe area at which the seal 217 is positioned around the electrochromicmedium 216. The opaque conducting layer 219 thus provides a contactingregion around the perimeter of the substrate for contacting thetransparent semi-conductive layers or coatings 218. The seal 217 ispositioned along the opaque conductive layer 219 and is thus masked orhidden by the opaque conductive layer to enhance the appearance of thereflective element assembly, particularly when the electro-optic orelectrochromic medium is darkened or colored. The opaque conductivelayer may thus allow for a smaller or no bezel overhang around theperimeter of the reflective element assembly. As can be seen in FIG. 36,the seal 217 may be positioned around the masked or border region of therear substrate 214. The non-conductive perimeter seal 217 at leastpartially fills or covers or encompasses the non-conductive glasssurface or masked region 214 e to electrically isolate or insulate theconductive coating 220 from the conductive adhesive 226, such that theconductive coating 220 of rear substrate 214 is electrically isolatedfrom the connector that connects to the conductive surface 218 of frontsubstrate 212.

Optionally, and as also described in PCT Application No. PCT/US03/35381,incorporated above, and with reference to FIGS. 37A and 37B, an exteriorrearview mirror cell or reflective element assembly for an exteriorrearview mirror assembly of a vehicle includes a first or frontsubstrate 312 (FIG. 37A) and a second or rear substrate 314 (FIG. 37B)and an electro-optic or electrochromic medium and seal 317 sandwichedtherebetween, such as described above. As also described above, thefront substrate 312 may have a transparent semi-conductive layer orcoating 318 (such as ITO or the like) applied to the second or rearsurface 312 a of the substrate, and may include an opaquifyingconductive border/perimeter coating or layer 319 (such as, for example,a black conductive epoxy or dark colored conductive frit or blackchrome/metallic chrome layer or the like) applied around the perimeteredges of the front substrate 312. As shown in FIG. 37A, the perimetercoating or layer 319 may be along the perimeter edges of the frontsubstrate 312 except in an electrical connection area or region 325 ofsubstrate 312, where the perimeter coating 319 is inward of the outeredges of substrate 312. The electrical connection region 325 is coatedby the semi-conductive layer 318 and/or a conductive layer or the like.A deletion line 321, such as a non-conductive area in the region 325where the busbar layer and semi-conductive layer is etched off orotherwise removed from or not applied to the surface of the substrate,is formed at the electrical connection area 325 to separate and defineand electrically isolate a rear substrate electrical connection area 325a or raceway portion of the semi-conductive layer from a front substrateelectrical connection area 325 b or surface portion of thesemi-conductive layer.

An electrical connection or contact 322 is connected to or applied tothe front substrate electrical connection area 325 b to provideelectrical power or connection to the semi-conductive layer 318 on therear surface of the front substrate 312. Likewise, an electricalconnection or contact 324 is connected to or applied to the electricallyisolated rear substrate electrical connection area 325 a and is inelectrical communication with the conductive layer of the third surface314 a of rear substrate 314 via a conductive material or bridge 323, asdiscussed below.

With reference to FIG. 37B, rear substrate 314 includes a metallicreflector layer 320 (such as a layer or layers comprising, for example,chromium, chromium/rhodium, aluminum, silver, aluminum alloy, silveralloy, an ITO/silver/ITO stack, an ITO/aluminum/ITO stack or the like,such as ITO-silver-ITO stacks or layers, or display on demand stacks orlayers or infrared transmitting stacks or layers of the types describedin PCT application No. PCT/US03/29776, filed Sep. 19, 2003 and publishedApr. 1, 2004 as International Publication No. WO 2004/026633) on itsfront or third surface 314 a, and a perimeter black seal 317 generallyaround the perimeter edges of the substrate. As can be seen in FIG. 37B,an electrical connection area 327 may be defined at a region of the rearsubstrate 314, such as at a corner of the substrate, where the perimeterseal 317 is positioned inward of the outer edge of the substrate. Therear substrate 314 is formed to be substantially identical in shape tothe front substrate 312, except at the electrical connection area 327,where the rear substrate may be cut back or reduced along a cut-away orcut back edge 314 c. The conductive bridge 323 is positioned at aportion of the electrical connection area 327 to provide electricalconnection to the metallic reflective coating or layer 320 viaelectrical connector 324 at front substrate 312.

When the substrates 312, 314 are placed together to form theelectro-optic or electrochromic mirror cell or reflective elementassembly (with the electro-optic or electrochromic medium disposed orsandwiched therebetween), the electrical connection area 327 of rearsubstrate 314 generally aligns with a portion of the electricalconnection area 325 of front substrate 312. The conductive bridge 323bridges or spans the gap or spacing between the electrical connectionareas 325 a and 327 to connect the electrical contact or connector 324and electrical connection area 325 a to the metallic conductivereflective layer 320 of rear substrate 314.

The cut-away edge 314 c of rear substrate 314 provides for exposure ofthe electrical connectors or contacts 322, 324 along the outer edge 312c of the electrical connection area 325 of front substrate 312. Theelectrical contacts for providing electrical power to the conductive orsemi-conductive layers at both substrates are made at only one of thesubstrates. The other edges of the substrates 312, 314 are generallyflush or aligned to form a flush reflective element assembly for anexterior rearview mirror assembly. The reflective element assembly maythus be implemented in a mirror assembly having a minimal bezel or abezelless mirror assembly to enhance the appearance of the mirrorassembly.

As disclosed in U.S. patent application Ser. No. 10/427,051, filed Apr.30, 2003, now U.S. Pat. No. 7,038,577, incorporated above, a camera orimaging sensor of an object detection system or lane change assistsystem is operable to capture an image of the exterior scene within thefield of view of the camera. The captured image comprises an image dataset, which is representative of the exterior scene, and which isreceived by the control. The control is operable to process image datawithin a reduced data set or subset of the image data set more thanother image data of the image data set to reduce the processingrequirements of the control. The reduced data set or subset or subsetsis/are representative of a target zone or area or areas in the exteriorscene where a vehicle or other object of interest may realistically beexpected to be present within the exterior scene. The control is thusoperable to primarily process the significant or relevant area or areasof the scene more than less relevant areas, and may limit or reduceprocessing of or substantially ignore the image data representative ofsome areas of the exterior scene where it is not likely that a vehicleor other object of interest would be present or where a vehicle cannotbe present.

The camera or imaging sensor may comprise an imaging array sensor, suchas a CMOS sensor or a CCD sensor or the like, such as disclosed incommonly assigned U.S. Pat. Nos. 5,550,677; 5,670,935; 5,796,094 and6,097,023, and U.S. patent application Ser. No. 09/441,341, filed Nov.16, 1999, now U.S. Pat. No. 7,339,149, or an extended dynamic rangecamera, such as the types disclosed in U.S. provisional application Ser.No. 60/426,239, filed Nov. 14, 2002. The imaging sensor may beimplemented and operated in connection with other vehicular systems aswell, or may be operable utilizing the principles of such othervehicular systems, such as a vehicle headlamp control system, such asthe type disclosed in U.S. Pat. No. 5,796,094, a rain sensor, such asthe types disclosed in commonly assigned U.S. Pat. Nos. 6,353,392;6,313,454 and/or 6,320,176, a vehicle vision system, such as a forwardlyor sidewardly or rearwardly directed vehicle vision system utilizing theprinciples disclosed in U.S. Pat. Nos. 5,550,677; 5,670,935 and6,201,642, and/or in U.S. patent application Ser. No. 09/199,907, filedNov. 25, 1998, now U.S. Pat. No. 6,717,610, a traffic sign recognitionsystem, a system for determining a distance to a leading vehicle orobject, such as utilizing the principles disclosed in U.S. Pat. No.6,396,397.

The camera preferably comprises a pixelated imaging array sensor whichhas a plurality of photon accumulating light sensors or pixels. Thecamera includes circuitry which is operable to individually access eachphotosensor pixel or element of the array of photosensor pixels and toprovide an output or image data set associated with the individualsignals to the control, such as via an analog to digital converter (notshown). As the camera receives light from objects and/or light sourcesin the target scene, the control may then be operable to process thesignal from at least some of the pixels to analyze the image data of thecaptured image, as discussed below.

The camera may be positioned along one or both sides of the vehicle,such as at or within the exterior rearview mirror at either or bothsides of the vehicle. However, the camera may be positioned elsewherealong either or both sides and/or at the rear of the vehicle anddirected sidewardly and rearwardly from the vehicle to capture an imageat either side of the vehicle, without affecting the scope of thepresent invention. The camera may be positioned at the vehicle andoriented or angled downwardly so as to capture an image which has anupper edge or region generally at the horizon. Positioning or orientingthe camera in such a manner provides for an increased horizontal pixelcount across the captured image at the important areas along the side ofthe vehicle, since any vehicle or significant object positioned at oralong a side of the subject vehicle will be substantially below thehorizon and thus substantially within the captured image. The lanechange assist system of the present invention thus may provide anincreased portion of the captured image or increased pixel count atimportant or significant or relevant areas of the exterior scene, sincethe area well above the road or horizon is not as significant to thedetection of a vehicle at or along a side of the subject vehicle.Additionally, positioning the camera to be angled generally downwardlyalso reduces the adverse effects that the sun and/or headlamps of othervehicles may have on the captured images. The camera thus may beoperable to capture substantially an entire image of the sideward scenebelow the horizon.

Changes and modification in the specifically described embodiments maybe carried out without departing from the principles of the presentinvention, which is intended to be limited only by the scope of theappended claims as interpreted according to the principles of patentlaw.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:
 1. An interior rearviewmirror assembly for a vehicle, said interior rearview mirror assemblycomprising: a prismatic interior mirror reflective element comprising aglass substrate; wherein said glass substrate has a front surface and arear surface opposite said front surface; wherein a mirror reflector isdisposed at said rear surface of said glass substrate of said mirrorreflective element and wherein said front surface of said glasssubstrate is angled relative to said rear surface of said glasssubstrate forming a prismatic glass substrate; wherein said frontsurface of said glass substrate comprises an outermost surface of saidmirror reflective element that is viewed by a driver of a vehicleequipped with said interior rearview mirror assembly; wherein said frontsurface of said glass substrate comprises a planar surface and whereinsaid glass substrate comprises a circumferential edge along a peripheryof said glass substrate; wherein said circumferential edge spans athickness of said glass substrate between said front surface and saidrear surface; a mounting element disposed at said rear surface of saidglass substrate of said mirror reflective element; wherein said mountingelement includes a pivot element that is configured to pivotally mountsaid mirror reflective element at a mounting structure disposed at aninterior portion of the equipped vehicle; a plastic molding thatreceives said mirror reflective element therein such that a portion ofsaid plastic molding is circumferentially disposed about saidcircumferential edge of said glass substrate without overlapping ontosaid front surface of said glass substrate; wherein a plane of saidfront surface of said glass substrate is flush with an outermost part ofsaid portion of said plastic molding; wherein said portion of saidplastic molding provides a curved rounded transition from said frontsurface of said glass substrate of said mirror reflective element to aside surface of said plastic molding; and wherein said plastic moldingcomprises at least a portion of a mirror housing of said interiorrearview mirror assembly.
 2. The interior rearview mirror assembly ofclaim 1, wherein said portion of said plastic molding curves fromadjacent to said front surface of said glass substrate to a less-curvedportion at said side surface of said plastic molding.
 3. The interiorrearview mirror assembly of claim 1, wherein said plastic moldingcomprises a soft touch material.
 4. The interior rearview mirrorassembly of claim 1, wherein said plastic molding and said mountingelement are formed together.
 5. The interior rearview mirror assembly ofclaim 1, wherein said plastic molding comprises structure for attachinga mirror housing cap portion thereat, and wherein, with said mirrorhousing cap portion attached at said structure, said mirror housing capportion at least partially encases said mounting element.
 6. Theinterior rearview mirror assembly of claim 1, wherein said mirrorreflective element nests in said plastic molding.
 7. The interiorrearview mirror assembly of claim 1, wherein said portion of saidplastic molding contacts said circumferential edge of said glasssubstrate.
 8. The interior rearview mirror assembly of claim 1, whereinsaid plastic molding has a durometer value less than about 110 Shore A.9. The interior rearview mirror assembly of claim 1, comprising a toggleassembly, wherein said pivot element is configured to pivotally mountsaid mirror reflective element at a double-ball mounting arm of themounting structure.
 10. The interior rearview mirror assembly of claim1, comprising a toggle assembly, wherein said pivot element isconfigured to pivotally mount said mirror reflective element at asingle-ball mounting arm of the mounting structure, and wherein thesingle-ball mounting arm comprises a ball pivot element with a wiringpassageway therethrough.